US20190327394A1 - Stereoscopic visualization camera and integrated robotics platform - Google Patents

Abstract

A robotic imaging apparatus is disclosed. A robotic imaging apparatus includes a robotic arm, a stereoscopic camera, and a sensor positioned between the robotic arm and the stereoscopic camera. The sensor transmits output data that is indicative of translational and rotational force imparted on the stereoscopic camera by an operator. The robotic imaging apparatus also includes a processor that is configured to determine a movement sequence for the robotic arm based on a current position of the robotic arm and the output data from the sensor and to cause at least one of the joints of the robotic arm to rotate based on the determined movement sequence via one or more motor control signals provided to the at least one joint. The rotation of the at least one joint provides power-assisted movement of the robotic arm based on the detected translational and rotational forces imparted by the operator.

Description

PRIORITY CLAIM
• The present application is a non-provisional of and claims priority to and the benefit of U.S. Provisional Patent Application No. 62/663,689, filed on Apr. 27, 2018, the entirety of which is incorporated herein by reference. The present application is also a continuation-in-part of U.S. patent application Ser. No. 15/814,127, filed Nov. 15, 2017, which claims priority to and the benefit of U.S. Provisional Patent Application No. 62/489,289 filed on Apr. 24, 2017 and U.S. Provisional Patent Application No. 62/489,876 filed on Apr. 25, 2017, the entirety of which are incorporated herein by reference.
BACKGROUND
• Surgery is art. Accomplished artists create works of art that far exceed the capabilities of a normal person. Artists use a brush to turn canisters of paint into vivid images that provoke strong and unique emotions from viewers. Artists take ordinary words written on paper and turn them into dramatic and awe-inspiring performances. Artists grasp instruments causing them to emit beautiful music. Similarly, surgeons take seemingly ordinary scalpels, tweezers, and probes and produce life-altering biological miracles.
• Like artists, surgeons have their own methods and preferences. Aspiring artists are taught the fundamentals of their craft. Beginners often follow prescribed methods. As they gain experience, confidence, and knowledge, they develop their own unique artistry reflective of themselves and their personal environment. Similarly, medical students are taught the fundamentals of surgical procedures. They are rigorously tested on these methods. As the students progress through residency and professional practice, they develop derivations of the fundamentals (still within medical standards) based on how they believe the surgery should best be completed. For instance, consider the same medical procedure performed by different renowned surgeons. The order of events, pacing, placement of staff, placement of tools, and use of imaging equipment varies between each of the surgeons based on their preferences. Even incision sizes and shapes can be unique to the surgeon.
• The artistic-like uniqueness and accomplishment of surgeons make them weary of surgical tools that change or alter their methods. The tool should be an extension of the surgeon, operating simultaneously and/or in harmonious synchronization. Surgical tools that dictate the flow of a procedure or change the rhythm of a surgeon are often discarded or modified to conform.
• In an example, consider microsurgery visualization where certain surgical procedures involve patient structures that are too small for a human to visualize easily with the naked eye. For these microsurgery procedures, magnification is required to adequately view the micro-structures. Surgeons generally want visualization tools that are natural extensions of their eyes. Indeed, early efforts at microsurgery visualization comprised attaching magnifying lens to head-mounted optical eyepieces (called surgical loupes). The first pair was developed in 1876. Vastly improved versions of surgical loupes (some including optical zooms and integrated light sources) are still being used by surgeons today.FIG. 1 shows a diagram of a pair ofsurgical loupes100 with alight source102 and magnification lenses104. The 150-year staying power of surgical loupes can be attributed to the fact that they are literally an extension of a surgeon's eyes.
• Despite their longevity, surgical loupes are not perfect. Loupes with magnifying lenses and light sources, such as theloupes100 ofFIG. 1, have much greater weight. Placing even a minor amount of weight on the front of a surgeon's face can increase discomfort and fatigue, especially during prolonged surgeries. Thesurgical loupes100 also include acable106 that is connected to a remote power supply. The cable effectively acts as a chain, thereby limiting the mobility of the surgeon during their surgical performance.
• Another microsurgery visualization tool is the surgical microscope, also referred to as the operating microscope. Widespread commercial development of surgical microscopes began in the 1950s with the intention of replacing surgical loupes. Surgical microscopes include optical paths, lenses, and focusing elements that provide greater magnification compared to surgical loupes. The large array of optical elements (and resulting weight) meant that surgical microscopes had to be detached from the surgeon. While this detachment gave the surgeon more room to maneuver, the bulkiness of the surgical microscope caused it to consume considerable operating space above a patient, thereby reducing the size of the surgical stage.
• FIG. 2 shows a diagram of a prior artsurgical microscope200. As one can imagine, the size and presence of the surgical microscope in the operating area made it prone to bumping. To provide stability and rigidity at thescope head201, the microscope is connected to relativelylarge boom arms202 and204 or other similar support structure. Thelarge boom arms202 and204 consume additional surgical space and reduce the maneuverability of the surgeon and staff. In total, thesurgical microscope200 shown inFIG. 2 could weigh as much as 350 kilograms (“kg”).
• To view a target surgical site using thesurgical microscope200, a surgeon looks directly though oculars206. To reduce stress on a surgeon's back, the oculars206 are generally positioned along a surgeon's natural line of sight using thearm202 to adjust height. However, surgeons do not perform by only looking at a target surgical site. Theoculars206 have to be positioned such that the surgeon is within arm's length of a working distance to the patient. Such precise positioning is critical to ensure thesurgical microscope200 becomes an extension rather than a hindrance to the surgeon, especially when being used for extended periods of time.
• Like any complex instrument, it takes surgeons tens to hundreds of hours to feel comfortable using a surgical microscope. As shown inFIG. 2, the design of thesurgical microscope200 requires a substantially 90° angle optical path from the surgeon to the target surgical site. For instance, a perfectly vertical optical path is required from the target surgical site to thescope head201. This means that thescope head201 has to be positioned directly above the patient for every microsurgical procedure. In addition, the surgeon has to look almost horizontally (or some slight angle downward) into the oculars206. A surgeon's natural inclination is to direct his vision to his hands at the surgical site. Some surgeons even want to move their heads closer to the surgical site to have more precise control of their hand movements. Unfortunately, thesurgical microscopes200 do not give surgeons this flexibility. Instead,surgical microscopes200 ruthlessly dictate that the surgeon is to place their eyes on theoculars206 and hold their head at arm's length during their surgical performance, all while consuming valuable surgical space above the patient. A surgeon cannot even simply look down at a patient because thescope head201 blocks the surgeon's view.
• To make matters worse, somesurgical microscopes200 include a second pair ofoculars208 for co-performers (e.g., assistant surgeons, nurses, or other clinical staff). The second pair ofoculars208 is usually positioned at a right angle from thefirst oculars206. The closeness between theoculars206 and208 dictates that the assistant must stand (or sit) in close proximity to the surgeon, further restricting movement. This can be annoying to some surgeons who like to perform with some space. Despite their magnification benefitssurgical microscopes200 are not natural extensions of a surgeon. Instead, they are overbearing directors in the surgical room.
SUMMARY
• The present disclosure is directed to a stereoscopic robotic system that includes a stereoscopic visualization camera and robotic arm. The example stereoscopic robotic system is configured to acquire stereoscopic images of a target surgical site while enabling an operator to position the stereoscopic visualization camera using the robotic arm. As disclosed herein, the robotic arm includes electro-mechanically operated joints that provide structurally stability to enable the stereoscopic visualization camera to record high-resolution images without jitter or other artifacts that can arise from unintended camera movement. The robotic arm also provides structural flexibility that permits an operator to position the stereoscopic visualization camera at different positions and/or orientations to obtain desired views of a target surgical site. The example stereoscopic robotic system accordingly enables a surgeon to complete life-altering microsurgeries comfortably in whatever position suits the surgeon.
• The stereoscopic robotic system of the present disclosure can be positioned about any number of orientations relative to the surgical field that best suits the needs of the surgeon or patient, rather than the physical and mechanical limitations of the visualization apparatus. The stereoscopic robotic system is configured to provide motorized joint movement assistance that enables a surgeon or other operator to effortlessly position the stereoscopic visualization camera. In some embodiments, the stereoscopic robotic system is configured to provide motorized assisted movement of a robotic arm based on forces detected from an operator positioning the stereoscopic camera. The stereoscopic robotic system may also enable an operator to select a visual lock on a target surgical site while enabling the operator to change an orientation and/or position of the stereoscopic visualization camera. Additionally or alternatively, the stereoscopic robotic system is configured with one or more boundaries that prevent the stereoscopic visualization camera and/or the robotic arm from contacting a patient, surgical staff, and/or surgical instruments. Altogether, the stereoscopic robotic system operates as an extension of a surgeon's eyes while giving the surgeon the freedom to conduct a microsurgery procedure generally without restrictions or impediments.
• Aspects of the subject matter described herein may be useful alone or in combination with one or more other aspect described herein. Without limiting the foregoing description, in a first aspect of the present disclosure, a robotic imaging apparatus includes a base section configured for connection to a secure structure or a cart and a robotic arm having a first end connected to the base section, a second end including a coupling interface, and a plurality of joints and links connecting the first end to the second end. Each joint includes a motor configured to rotate the joint around an axis and a joint sensor configured to transmit a position of the respective joint. The robotic imaging apparatus also includes a stereoscopic camera connected to the robotic arm at the coupling interface. The stereoscopic camera is configured to record left and right images of a target surgical site for producing a stream of stereoscopic images of the target surgical site. The robotic imaging apparatus further includes a sensor positioned at the coupling interface and configured to detect and transmit output data that is indicative of translational and rotational force imparted on the stereoscopic camera by an operator. The robotic imaging apparatus additionally includes a memory storing at least one algorithm defined by one or more instructions and/or data structures that specify a rotation direction, speed, and duration for each of the joints of the robotic arm based at least on a current position of the robotic arm and detected translational and rotational forces. Moreover, the robotic imaging apparatus includes at least one processor communicatively coupled to the sensor and the robotic arm. The at least one processor configured to receive the output data from the sensor that is indicative of the translational and rotational forces and determine, using the at least one algorithm in the memory, a movement sequence for the robotic arm based on a current position of the robotic arm and the output data from the sensor. The at least one processor is also configured to cause at least one of the joints of the robotic arm to rotate based on the determined movement sequence via one or more motor control signals provided to the at least one joint. The rotation of the at least one joint provides power-assisted movement of the robotic arm based on the detected translational and rotational forces imparted on the stereoscopic camera by the operator.
• In accordance with a second aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the at least one processor is configured to determine the current position of the robotic arm based on output data from the joint sensors of the plurality of joints.
• In accordance with a third aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the sensor includes at least one of a six-degrees-of-freedom haptic force-sensing device or a torque sensor.
• In accordance with a fourth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the stereoscopic camera includes at least one control arm having a release button to enable the power-assisted movement, and the at least one processor is configured to receive an input message indicative that the release button was selected, and determine the movement sequence using the output data from the sensor after receiving the input message related to the release button.
• In accordance with a fifth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the apparatus further includes a coupling plate with a first end configured to connect to the coupling interface of the robotic arm and a second end including a second coupling interface configured to connect to the stereoscopic camera. The coupling plate includes at least one joint including a joint sensor configured to transmit a position of the respective joint and a motor that is controllable by the at least one processor according to the movement sequence.
• In accordance with a sixth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the sensor is located at the coupling interface or the second coupling interface.
• In accordance with a seventh aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the coupling plate includes a second joint that enables the stereoscopic camera to be manually rotated by an operator between a horizontal orientation and a vertical orientation. The second joint includes a joint sensor configured to transmit a position of the second joint.
• In accordance with an eighth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the stereoscopic camera includes a housing including a bottom side that is configured to connect to the robotic arm at the coupling interface.
• In accordance with a ninth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, a robotic imaging apparatus includes a robotic arm comprising a first end for connection to a secure structure, a second end including a coupling interface, and a plurality of joints and links connecting the first end to the second end, each joint including a motor configured to rotate the joint around an axis and a joint sensor configured to transmit a position of the respective joint. The robotic imaging apparatus also includes an imaging device connected to the robotic arm at the coupling interface, the imaging device configured to record images of a target surgical site, and a sensor positioned at the coupling interface and configured to detect and transmit force and/or torque output data that is indicative of force and/or torque imparted on the imaging device by an operator. The robotic imaging apparatus further includes at least one processor communicatively coupled to the sensor and the robotic arm. The at least one processor is configured to receive the force and/or torque output data from the sensor, convert the force and/or torque output data into translational and rotational vectors, determine, using kinematics, a movement sequence for the robotic arm based on a current position of the robotic arm and the translational and rotational vectors, the movement sequence specifying a rotation direction, a speed, and a duration of movement for at least some of the joints of the robotic arm, and cause at least one of the joints of the robotic arm to rotate based on the determined movement sequence via one or more motor control signals provided to the at least one joint.
• In accordance with a tenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to determine a least one scale factor based on at least one of the current position of the robotic arm or a future position of the robotic arm based on the movement sequence, and apply the scale factor to at least one joint speed of the movement sequence.
• In accordance with an eleventh aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the at least one scale factor is configured based on a distance of the robotic arm or the imaging device from a virtual boundary. The at least one scale factor decreases to a value of ‘0’ as the virtual boundary is approached.
• In accordance with a twelfth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the virtual boundary corresponds to at least one of a patient, a medical instrument, or operating room staff
• In accordance with a thirteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to cause a display device to display an icon indicative that the at least one scale factor has been applied to the movement sequence.
• In accordance with a fourteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to determine a least one scale factor based on joint angles between joints of the robotic arm or joint limits, and apply the scale factor to at least one joint speed of the movement sequence.
• In accordance with a fifteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to provide gravity compensation for the force and/or torque output data, and provide force-application compensation for the force and/or torque output data to compensate for an offset between a location of the sensor and a location of the imaging device upon which the force and/or torque is imparted by the operator.
• In accordance with a sixteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to determine or identify joint singularities for the plurality of joints of the robotic arm for control of hysteresis and backlash, and determine the movement sequence based on the kinematics while avoiding robotic arm movement through the joint singularities.
• In accordance with a seventeenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the robotic imaging apparatus further includes a coupling plate with a first end configured to connect to the coupling interface of the robotic arm and a second end including a second coupling interface configured to connect to the stereoscopic camera. The coupling plate includes at least one joint including a joint sensor configured to transmit a position of the respective joint and a motor that is controllable by the at least one processor according to the movement sequence. The sensor is located at the coupling interface or the second coupling interface.
• In accordance with an eighteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the robotic arm includes at least four joints and the coupling plate includes at least two joints.
• In accordance with a nineteenth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to cause at least one of the joints of the robotic arm to rotate by transmitting one or more command signals to the motor of the respective joint indicative of the rotation direction, the speed, and the duration of movement as specified by the movement sequence.
• In accordance with a twentieth aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the processor is configured to compare images recorded by the imaging device as the robotic arm is being moved during the movement sequence to confirm the robotic arm is being moved as specified during the movement sequence.
• In accordance with a twenty-first aspect of the present disclosure, which may be used in combination with any other aspect listed herein unless stated otherwise, the kinematics includes at least one of inverse kinematics or Jacobean kinematics.
• In accordance with a twenty-second aspect of the present disclosure, any of the structure and functionality illustrated and described in connection withFIGS. 3 to 65 may be used in combination with any of the structure and functionality illustrated and described in connection with any of the other ofFIGS. 3 to 65 and with any one or more of the preceding aspects.
• In light of the aspects above and the disclosure herein, it is accordingly an advantage of the present disclosure to provide a stereoscopic robotic system that provides seamless coordination between a stereoscopic camera and a robotic arm.
• It is another advantage of the present disclosure to provide a stereoscopic robotic system that uses a robotic arm to increase a focal range, working distance, and/or magnification of a stereoscopic robotic system.
• It is a further another advantage of the present disclosure to provide a stereoscopic robotic system that provides powered assisted movement of the robotic arm based on forces/torques imparted on a stereoscopic camera by an operator.
• The advantages discussed herein may be found in one, or some, and perhaps not all of the embodiments disclosed herein. Additional features and advantages are described herein, and will be apparent from the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE FIGURES
• FIG. 1 shows a diagram of a pair of prior art surgical loupes.
• FIG. 2 shows a diagram of a prior art surgical microscope.
• FIGS. 3 and 4 show diagrams of perspective views of a stereoscopic visualization camera, according to an example embodiment of the present disclosure.
• FIGS. 5 and 6 show diagrams of a microsurgical environment including the stereoscopic visualization camera ofFIGS. 3 and 4, according to example embodiments of the present disclosure.
• FIGS. 7 and 8 show diagrams illustrative of optical elements within the example stereoscopic visualization camera ofFIGS. 3 to 6, according to an example embodiment of the present disclosure.
• FIG. 9 shows a diagram of a deflecting element of the example stereoscopic visualization camera ofFIGS. 7 and 8, according to an example embodiment of the present disclosure.
• FIG. 10 shows a diagram of an example of a right optical image sensor and a left optical image sensor of the example stereoscopic visualization camera ofFIGS. 7 and 8, according to an example embodiment of the present disclosure.
• FIGS. 11 and 12 show diagrams of example carriers for optical elements of the example stereoscopic visualization camera ofFIGS. 7 and 8, according to example embodiments of the present disclosure.
• FIG. 13 shows a diagram of an example flexure of the example stereoscopic visualization camera ofFIGS. 7 and 8, according to an example embodiment of the present disclosure.
• FIG. 14 shows a diagram of modules of the example stereoscopic visualization camera for acquiring and processing image data, according to an example embodiment of the present disclosure.
• FIG. 15 shows a diagram of internal components of the modules ofFIG. 14, according to an example embodiment of the present disclosure.
• FIG. 16 shows a diagram of an information processor module ofFIGS. 14 and 15, according to an example embodiment of the present disclosure.
• FIG. 17 shows an example of a display monitor, according to an example embodiment of the present disclosure.
• FIGS. 18 to 21 show diagrams illustrative of spurious parallax between right and left optical paths.
• FIG. 22 shows a diagram illustrative of an out-of-focus condition in relation to a position of two parallel lenses for respective right and left optical paths.
• FIGS. 23 and 24 show diagrams illustrative of how spurious parallax causes digital graphics and/or images to lose accuracy when fused to a stereoscopic image.
• FIGS. 25 and 26 illustrate a flow diagram showing an example procedure to reduce or eliminate spurious parallax, according to an example embodiment of the present disclosure.
• FIG. 27 shows a diagram illustrative of how a zoom repeat point is adjusted with respect to a pixel grid of an optical image sensor, according to an example embodiment of the present disclosure.
• FIGS. 28 to 32 show diagrams illustrative of a template matching program to locate a zoom repeat point, according to an example embodiment of the present disclosure.
• FIG. 33 shows a side-view of the microsurgical environment ofFIG. 5, according to an example embodiment of the present disclosure.
• FIG. 34 shows an embodiment of the example robotic arm ofFIG. 5, according to an example embodiment of the present disclosure.
• FIG. 35 shows a diagram of the robotic arm ofFIGS. 33 and 34 connected to a cart, according to an example embodiment of the present disclosure.
• FIG. 36 shows a diagram where the robotic arm ofFIGS. 33 and 34 is mounted to a ceiling plate, according to an example embodiment of the present disclosure.
• FIG. 37 shows an embodiment of a coupling plate for the robotic arm, according to an example embodiment of the present disclosure.
• FIGS. 38 to 40 show diagrams of the coupling plate in different rotational positions, according to example embodiments of the present disclosure.
• FIG. 41 illustrates an embodiment of the stereoscopic robotic platform ofFIGS. 3 to 40, according to an example embodiment of the present disclosure.
• FIG. 42 illustrates an example procedure or routine for calibrating the stereoscopic visualization camera ofFIGS. 3 to 33, according to an example embodiment of the present disclosure.
• FIG. 43 shows an embodiment of the example stereoscopic visualization camera ofFIGS. 3 to 33 and 42 moving an object plane in discrete steps, according to an example embodiment of the present disclosure.
• FIG. 44 illustrates a graph illustrative of a routine executable by a processor for determining a center-of-projection of the stereoscopic visualization camera ofFIGS. 3 to 33 and 42, according to an example embodiment of the present disclosure.
• FIG. 45 shows a plan view of an optical schematic that is illustrative of how an interpupillary distance of the stereoscopic visualization camera ofFIGS. 3 to 33 is measured and calibrated, according to an example embodiment of the present disclosure.
• FIG. 46 shows a plan view of an optical schematic that is illustrative of how an optical axis of the stereoscopic visualization camera ofFIGS. 3 to 33 may be measured and calibrated, according to an example embodiment of the present disclosure.
• FIG. 47 illustrates a diagram of a calibrated stereoscopic visualization camera in which optical parameters are fully characterized, according to an example embodiment of the present disclosure.
• FIG. 48 illustrates an example procedure or routine for calibrating the robotic arm ofFIGS. 5 and 33 to 41, according to an example embodiment of the present disclosure.
• FIG. 49 shows a diagram that is illustrative of how the stereoscopic visualization camera and/or the robotic arm are calibrated to robot space, according to an example embodiment of the present disclosure.
• FIG. 50 shows a diagram illustrative of horizontal and vertical boundary planes for restricting movement of the stereoscopic visualization camera and/or the robotic arm, according to an example embodiment of the present disclosure.
• FIG. 51 illustrates an example of how rotational joint speed of the robotic arm and/or the coupling plate is scaled based on distance to a boundary, according to an example embodiment of the present disclosure.
• FIG. 52 shows a diagram of an example procedure for fusing an image from an alternate modality visualization with stereoscopic image(s), according to an example embodiment of the present disclosure.
• FIGS. 53 to 61 show diagrams illustrative of live cross-sectional fused visualizations generated by the combination of the stereoscopic visualization camera and/or the robotic arm ofFIGS. 3 to 52, according to example embodiments of the present disclosure.
• FIG. 62 shows a diagram that is illustrative of a procedure for providing assisted drive of the stereoscopic visualization camera ofFIGS. 3 to 52, according to an example embodiment of the present disclosure.
• FIG. 63 shows a diagram of an example procedure for moving the example visualization camera ofFIGS. 3 to 52 using an input device, according to an example embodiment of the present disclosure.
• FIG. 64 shows a diagram that is illustrative of an algorithm, routine, or procedure for providing a lock-to-target for the stereoscopic visualization camera, according to an example embodiment of the present disclosure.
• FIG. 65 shows a diagram that is illustrative of a virtual sphere for the lock-to-target feature ofFIG. 64, according to an example embodiment of the present disclosure.
DETAILED DESCRIPTION
• The present disclosure relates in general to a stereoscopic visualization camera and platform. The stereoscopic visualization camera may be referred to as a digital stereoscopic microscope (“DSM”). The example camera and platform are configured to integrate microscope optical elements and video sensors into a self-contained head unit that is significantly smaller, lighter, and more maneuverable than prior art microscopes (such as thesurgical loupes100 ofFIG. 1 and thesurgical microscope200 ofFIG. 2). The example camera is configured to transmit a stereoscopic video signal to one or more television monitors, projectors, holographic devices, smartglasses, virtual reality devices, or other visual display devices within a surgical environment.
• The monitors or other visual display devices may be positioned within the surgical environment to be easily within a surgeon's line of sight while performing surgery on a patient. This flexibility enables the surgeon to place display monitors based on personal preferences or habits. In addition, the flexibility and slim profile of the stereoscopic visualization camera disclosed herein reduces area consumed over a patient. Altogether, the stereoscopic visualization camera and monitors (e.g., the stereoscopic visualization platform) enables a surgeon and surgical team to perform complex microsurgical surgical procedures on a patient without being dictated or restricted in movement compared to thesurgical microscope200 discussed above. The example stereoscopic visualization platform accordingly operates as an extension of the surgeon's eyes, enabling the surgeon to perform masterpiece microsurgeries without dealing with the stress, restrictions, and limitations induced by previous known visualization systems.
• The disclosure herein generally refers to microsurgery. The example stereoscopic visualization camera may be used in virtually any microsurgical procedure including, for example, cranial surgery, brain surgery, neurosurgery, spinal surgery, ophthalmologic surgery, corneal transplants, orthopedic surgery, ear, nose and throat surgery, dental surgery, plastics and reconstructive surgery, or general surgery.
• The disclosure also refers herein to target site, scene, or field-of-view. As used herein, target site or field-of-view includes an object (or portion of an object) that is being recorded or otherwise imaged by the example stereoscopic visualization camera. Generally the target site, scene, or field-of-view is a working distance away from a main objective assembly of the example stereoscopic visualization camera and is aligned with the example stereoscopic visualization camera. The target site may include a patient's biological tissue, bone, muscle, skin or combinations thereof. In these instances, the target site may be three dimensional by having a depth component corresponding to a progression of a patient's anatomy. The target site may also include one or more templates used for calibration or verification of the example stereoscopic visualization camera. The templates may be two-dimensional, such as a graphic design on paper (or plastic sheet) or three dimensional, such as to approximate a patient's anatomy in a certain region.
• Reference is also made throughout to an x-direction, a y-direction, a z-direction, and a tilt-direction. The z-direction is along an axis from the example stereoscopic visualization camera to the target site and generally refers to depth. The x-direction and y-direction are in a plane incident to the z-direction and comprise a plane of the target site. The x-direction is along an axis that is 90° from an axis of the y-direction. Movement along the x-direction and/or the y-direction refer to in-plane movement and may refer to movement of the example stereoscopic visualization camera, movement of optical elements within the example stereoscopic visualization camera, and/or movement of the target site.
• The tilt-direction corresponds to movement along Euler angles (e.g., a yaw axis, a pitch axis, and a roll axis) with respect to the x-direction, the y-direction, and/or the z-direction. For example, a perfectly aligned lens has substantially a 0° tilt with respect to the x-direction, the y-direction, and/or the z-direction. In other words, a face of the lens is 90° or perpendicular to light along the z-direction. In addition, edges of the lens (if the lens has a rectangular shape) are parallel along the x-direction and the y-direction. Lens and/or optical image sensors can be titled through yaw movement, pitch movement, and/or roll movement. For example, a lens and/or optical image sensor may be titled along a pitch axis, with respect to the z-direction, to face upwards or downwards. Light along the z-direction contacts a face of a lens (that is pitched upwards or downwards) at non-perpendicular angle. Tilting of a lens and/or optical image sensor along a yaw axis, pitch axis, or roll axis enables, for example, a focal point or ZRP to be adjusted.
I. Example Stereoscopic Visualization Camera
• FIGS. 3 and 4 show diagrams of perspective views of astereoscopic visualization camera300, according to an example embodiment of the present disclosure. Theexample camera300 includes ahousing302 configured to enclose optical elements, lens motors (e.g., actuators), and signal processing circuitry. Thecamera300 has a width (along an x-axis) between 15 to 28 centimeters (cm), preferably around 22 cm. In addition, thecamera300 has a length (along a y-axis) between 15 to 32 cm, preferably around 25 cm. Further, thecamera300 has a height (along a z-axis) between 10 to 20 cm, preferably around 15 cm. The weight of thecamera300 is between 3 to 7 kg, preferably around 3.5 kg.
• Thecamera300 also includescontrol arms304aand304b(e.g., operating handles), which are configured to control magnification level, focus, and other microscope features. Thecontrol arms304aand304bmay includerespective controls305aand305bfor activating or selecting certain features. For example, thecontrol arms304aand304bmay includecontrols305aand305bfor selecting a fluorescence mode, adjusting an amount/type of light projected onto a target site, and controlling a display output signal (e.g., selection between 1080p or 4K and/or stereoscopic). In addition, thecontrols305aand/or305bmay be used to initiate and/or perform a calibration procedure and/or move a robotic arm connected to thestereoscopic visualization camera300. In some instances, thecontrols305aand305bmay include the same buttons and/or features. In other instances thecontrols305aand305bmay include different features. Further, thecontrol arms304aand304bmay also be configured as grips to enable an operator to position thestereoscopic visualization camera300.
• Each control arm304 is connected to thehousing302 via a rotatable post306, as shown inFIG. 3. This connection enables the control arms304 to be rotated with respect to thehousing302. This rotation provides flexibility to a surgeon to arrange the control arms304 as desired, further enhancing the adaptability of thestereoscopic visualization camera300 to be in synchronization with a surgical performance.
• While theexample camera300 shown inFIGS. 3 and 4 includes twocontrol arms304aand304b, it should be appreciated that thecamera300 may only include one control arm or zero control arms. In instances where thestereoscopic visualization camera300 does not include a control arm, controls may be integrated with thehousing302 and/or provided via a remote control.
• FIG. 4 shows a bottom-up perspective view of a rear-side of thestereoscopic visualization camera300, according to an example embodiment of the present disclosure. Thestereoscopic visualization camera300 includes a mountingbracket402 configured to connect to a support. As described in more detail inFIGS. 5 and 6, the support may include an arm with one or more joints to provide significant maneuverability. The arm may be connected to a movable cart or secured to a wall or ceiling.
• Thestereoscopic visualization camera300 also includes apower port404 configured to receive a power adapter. Power may be received from an AC outlet and/or a battery on a cart. In some instances, thestereoscopic visualization camera300 may include an internal battery to facilitate operation without cords. In these instances, thepower port404 may be used to charge the battery. In alternative embodiments, thepower port404 may be integrated with the mountingbracket402 such that thestereoscopic visualization camera300 receives power via wires (or other conductive routing materials) within the support.
• FIG. 4 also shows that thestereoscopic visualization camera300 may include adata port406. Theexample data port406 may include any type of port including, for example, an Ethernet interface, a high-definition multimedia interface (“HDMI”) interface, a universal serial bus (“USB”) interface, a Serial Digital Interface (“SDI”), a digital optical interface, an RS-232 serial communication interface etc. Thedata port406 is configured to provide a communicative connection between thestereoscopic visualization camera300 and cords routed to one or more computing devices, servers, recording devices, and/or display devices. The communicative connection may transmit stereoscopic video signals or two-dimensional video signals for further processing, storage, and/or display. Thedata port406 may also enable control signals to be sent to thestereoscopic visualization camera300. For instance, an operator at a connected computer (e.g., a laptop computer, desktop computer, and/or tablet computer) may transmit control signals to thestereoscopic visualization camera300 to direct operation, perform calibration, or change an output display setting.
• In some embodiments, thedata port406 may be replaced (and/or supplemented) with a wireless interface. For example, thestereoscopic visualization camera300 may transmit stereoscopic display signals via Wi-Fi to one or more display devices. A use of a wireless interface, combined with an internal battery, enables thestereoscopic visualization camera300 to be wire-free, thereby further improving maneuverability within a surgical environment.
• Thestereoscopic visualization camera300 shown inFIG. 4 also includes a front working distance mainobjective lens408 of a main objective assembly. Theexample lens408 is the start of the optical path within thestereoscopic visualization camera300. Light from a light source internal to thestereoscopic visualization camera300 is transmitted through thelens408 to a target site. Additionally, light reflected from the target site is received in thelens408 and passed to downstream optical elements.
II. Exemplary Maneuverability of the Stereoscopic Visualization Camera
• FIGS. 5 and 6 show diagrams of thestereoscopic visualization camera300 used within amicrosurgical environment500, according to example embodiments of the present disclosure. As illustrated, the small footprint and maneuverability of the stereoscopic visualization camera300 (especially when used in conjunction with a multiple-degree of freedom arm) enables flexible positioning with respect to apatient502. A portion of thepatient502 in view of thestereoscopic visualization camera300 includes atarget site503. Asurgeon504 can position thestereoscopic visualization camera300 in virtually any orientation while leaving more than sufficient surgical space above the patient502 (lying in the supine position). Thestereoscopic visualization camera300 accordingly is minimally intrusive (or not intrusive) to enable thesurgeon504 to perform a life-altering microsurgical procedure without distraction or hindrance.
• InFIG. 5, thestereoscopic visualization camera300 is connected to amechanical arm506 via mountingbracket402. Thearm506 may include one or more rotational or extendable joints with electromechanical brakes to facilitate easy repositioning of thestereoscopic visualization camera300. To move thestereoscopic visualization camera300, thesurgeon504, or theassistant508, actuates brake releases on one or more joints of thearm506. After thestereoscopic visualization camera300 is moved into a desired position, the brakes may be engaged to lock the joints of thearm506 in place.
• A significant feature of thestereoscopic visualization camera300 is that it does not include oculars. This means that thestereoscopic visualization camera300 does not have to be aligned with the eyes of thesurgeon504. This freedom enables thestereoscopic visualization camera300 to be positioned and orientated in desirable positions that were not practical or possible with prior known surgical microscopes. In other words, thesurgeon504 can perform microsurgery with the most optimal view for conducting the procedure rather than being restricted to merely adequate view dictated by oculars of a surgical microscope.
• Returning toFIG. 5, thestereoscopic visualization camera300, via themechanical arm506, is connected to acart510 with display monitors512 and514 (collectively a stereoscopic visualization platform or stereoscopic robotic platform516). In the illustrated configuration, thestereoscopic visualization platform516 is self-contained and may be moved to any desired location in themicrosurgical environment500 including between surgical rooms. Theintegrated platform516 enables thestereoscopic visualization camera300 to be moved and used on-demand without time needed to configure the system by connecting the display monitors512 and514.
• The display monitors512 and514 may include any type of display including a high-definition television, an ultra-high definition television, smart-eyewear, projectors, one or more computer screens, laptop computers, tablet computers, and/or smartphones. The display monitors512 and514 may be connected to mechanical arms to enable flexible positioning similar to thestereoscopic visualization camera300. In some instances, the display monitors512 and514 may include a touchscreen to enable an operator to send commands to thestereoscopic visualization camera300 and/or adjust a setting of a display.
• In some embodiments, thecart516 may include acomputer520. In these embodiments, thecomputer520 may control a robotic mechanical arm connected to thestereoscopic visualization camera300. Additionally or alternatively, thecomputer520 may process video (or stereoscopic video) signals (e.g., an image or frame stream) from thestereoscopic visualization camera300 for display on the display monitors512 and514. For example, thecomputer520 may combine or interleave left and right video signals from thestereoscopic visualization camera300 to create a stereoscopic signal for displaying a stereoscopic image of a target site. Thecomputer520 may also be used to store video and/or stereoscopic video signals into a video file (stored to a memory) so the surgical performance can be documented and played back. Further, thecomputer520 may also send control signals to thestereoscopic visualization camera300 to select settings and/or perform calibration.
• In some embodiments, themicrosurgical environment500 ofFIG. 5 includes an ophthalmic surgery procedure. In this embodiment, themechanical arm506 may be programmed to perform an orbiting sweep of a patient's eye. Such a sweep enables the surgeon to examine a peripheral retina during vitreo-retinal procedures. In contrast, with conventional optical microscopes, the only way a surgeon can view the peripheral retina is to push the side of the eye into the field of view using a technique known as scleral depression.
• FIG. 6 shows a diagram of themicrosurgical environment500 with thepatient502 in a sitting position for a posterior-approach skull base neurosurgery. In the illustrated embodiment, thestereoscopic visualization camera300 is placed into a horizontal position to face the back of the head of thepatient502. Themechanical arm506 includes joints that enable thestereoscopic visualization camera300 to be positioned as shown. In addition, thecart510 includes themonitor512, which may be aligned with the surgeon's natural view direction.
• The absence of oculars enables thestereoscopic visualization camera300 to be positioned horizontally and lower than the eye-level view of thesurgeon504. Further, the relatively low weight and flexibility enables thestereoscopic visualization camera300 to be positioned in ways unimaginable for other known surgical microscopes. Thestereoscopic visualization camera300 thereby provides a microsurgical view for any desired position and/or orientation of thepatient502 and/or thesurgeon504.
• WhileFIGS. 5 and 6 show two example embodiments for positioning thestereoscopic visualization camera300, it should be appreciated that thestereoscopic visualization camera300 may be positioned in any number of positions depending on the number of degrees of freedom of themechanical arm506. It is entirely possible in some embodiments to position thestereoscopic visualization camera300 to face upwards (e.g., upside down).
III. Comparison of the Example Stereoscopic Visualization Platform to Known Surgical Microscopes
• In comparing thestereoscopic visualization camera300 ofFIGS. 3 to 6 to thesurgical microscope200 ofFIG. 2, the differences are readily apparent. The inclusion ofoculars206 with the surgical microscope requires that the surgeon constantly orient his/her eyes to eyepieces, which are in a fixed location relative to thescope head201 and patient. Further, the bulkiness and weight of the surgical microscope restricts it to being positioned only in a generally vertical orientation with respect to a patient. In contrast, the examplestereoscopic visualization camera300 does not include oculars and may be positioned in any orientation or position with respect to a patient, thereby freeing the surgeon to move during surgery.
• To enable other clinician staff to view a microsurgical target site, thesurgical microscope200 requires the addition ofsecond oculars208. Generally, most knownsurgical microscopes200 do not allow adding third oculars. In contrast, the examplestereoscopic visualization camera300 may be communicatively coupled to an unlimited number of display monitors. WhileFIGS. 5 and 6 above showed display monitors512 and514 connected to cart510, a surgical room may be surrounded in display monitors that all show the microsurgical view recorded by thestereoscopic visualization camera300. Thus, instead of limiting a view to one or two people (or requiring sharing an ocular), an entire surgical team can view a magnified view of a target surgical site. Moreover, people in other rooms, such as training and observation rooms, can be presented with the same magnified view displayed to the surgeon.
• Compared to thestereoscopic visualization camera300, the two-ocularsurgical microscope200 is more prone to being bumped or inadvertently moved. Since surgeons place their heads onoculars206 and208 during surgery to look through eyepieces, thescope head201 receives constant force and periodic bumps. Adding thesecond oculars208 doubles the force from a second angle. Altogether, the constant force and periodic bumping by the surgeons may cause thescope head201 to move, thereby requiring thescope head201 to be repositioned. This repositioning delays the surgical procedure and annoys the surgeon.
• The examplestereoscopic visualization camera300 does not include oculars and is not intended to receive contact from a surgeon once it is locked into place. This corresponds to a significantly lower chance of thestereoscopic visualization camera300 being accidentally moved or bumped during the surgeon's performance.
• To facilitate thesecond oculars208, thesurgical microscope200 has to be outfitted with abeamsplitter210, which may include glass lenses and mirrors housed in precision metallic tubes. The use of abeamsplitter210 reduces light received at the first oculars because some of the light is reflected to thesecond oculars208. Further, addition of thesecond oculars208 and thebeamsplitter210 increases the weight and bulkiness of thescope head201.
• In contrast to thesurgical microscope200, thestereoscopic visualization camera300 only contains optical paths for sensors, thereby reducing weight and bulkiness. In addition, the optical sensors receive the full incident light since beamsplitters are not needed to redirect a portion of the light. This means the image received by optical sensors of the examplestereoscopic visualization camera300 is as bright and clear as possible.
• Some models of surgical microscopes may enable a video camera to be attached. For instance, thesurgical microscope200 ofFIG. 2 includes amonoscopic video camera212 connected to an optical path viabeamsplitter214. Thevideo camera212 may be monoscopic or stereoscopic, such as the Leica® TrueVision® 3D Visualization System Ophthalmology camera. Thevideo camera212 records an image received from thebeamsplitter214 for display on a display monitor. The addition of thevideo camera212 andbeamsplitter214 further add to the weight of thescope head201. In addition, thebeamsplitter214 consumes additional light destined for theoculars206 and/or208.
• Eachbeamsplitter210 and214 divides the incident light fractionally into three paths, removing light from the surgeon's view. The surgeon's eye has limited low-light sensitivity such that light from the operative site presented to him/her must be sufficient to allow the surgeon to perform the procedure. However, a surgeon cannot always increase the intensity of light applied to a target site on a patient, especially in ophthalmological procedures. A patient's eye has limited high-light sensitivity before it develops light toxicity. Hence, there is a limitation to the number and fraction of beamsplitters and to the amount of light which can be split off from thefirst oculars206 to enable the use ofancillary devices208 and212.
• The examplestereoscopic visualization camera300 ofFIGS. 3 to 6 does not include beamsplitters such that optical imaging sensors receive the full amount of light from a main objective assembly. This enables the use of sensors with low-light sensitivity or even optical sensors with sensitivity outside the wavelengths of visible light to be used since post-processing can make the images sufficiently bright and visible (and adjustable) for display on the monitors.
• Further, since the optical elements that define the optical paths are self-contained within thestereoscopic visualization camera300, the optical elements may be controlled through the camera. This control allows placement and adjustment of the optical elements to be optimized for a three-dimensional stereoscopic display rather than for microscope oculars. This configuration of the camera permits control to be provided electronically from camera controls or from a remote computer. In addition, the control may be provided automatically through one or more programs onboard thecamera300 configured to adjust optical elements for retaining focus while zooming or to adjust for optical defects and/or spurious parallax. In contrast, optical elements of thesurgical microscope200 are external to thevideo camera212 and controlled only via operator input, which is generally optimized for viewing a target site through theoculars206.
• In a final comparison, thesurgical microscope200 includes anX-Y panning device220 for moving a field-of-view or target scene. TheX-Y panning device220 is typically a large, heavy, and expensive electromechanical module since it must rigidly support and move thesurgical scope head201. In addition, moving thescope head201 changes the positioning of the surgeon to the new location of theoculars206.
• In contrast, the examplestereoscopic visualization camera300 includes a memory including instructions, which when executed, cause a processor to select pixel data of optical sensors to enable X-Y panning across a wide pixel grid. In addition, the examplestereoscopic visualization camera300 may include a small motor or actuator that controls a main objective optical element to change a working distance to a target site without moving thecamera300.
IV. Example Optical Elements of the Stereoscopic Visualization Camera
• FIGS. 7 and 8 show diagrams illustrative of optical elements within the examplestereoscopic visualization camera300 ofFIGS. 3 to 6, according to an example embodiment of the present disclosure. It may seem relatively simple to acquire left and right views of a target site to construct a stereoscopic image. However, without careful design and compensation, many stereoscopic images have alignment issues between the left and right views. When viewed for a prolonged period of time, alignment issues can create confusion in an observer's brain as a result of differences between the left and right views. This confusion can lead to headaches, fatigue, vertigo, and even nausea.
• The examplestereoscopic visualization camera300 reduces (or eliminates) alignment issues by having a right optical path and left optical path with independent control and/or adjustment of some optical elements while other left and right optical elements are fixed in a common carrier. In an example embodiment, some left and right zoom lenses may be fixed to a common carrier to ensure left and right magnification is substantially the same. However, front or rear lenses may be independently adjustable radially, rotationally, axially, and/or tilted to compensate for small differences in zoom magnification, visual defects, and/or spurious parallax such as movement of a zoom repeat point. Compensation provided by adjustable lenses results in almost perfectly aligned optical paths throughout a complete zoom magnification range.
• Additionally or alternatively, alignment issues may be reduced (or eliminated) using pixel readout and/or rendering techniques. For example, a right image (recorded by a right optical sensor) may be adjusted upwards or downwards with respect to a left image (recorded by a left optical sensor) to correct vertical misalignment between the images. Similarly, a right image may be adjusted left or right with respect to a left image to correct horizontal misalignment between the images.
• FIGS. 7 and 8 below show an example arrangement and positioning of optical elements that provide for almost artifact, spurious parallax, and distortion-free aligned optical paths. As discussed later, certain of the optical elements may be moved during calibration and/or use to further align the optical paths and remove any remaining distortions, spurious parallax, and/or defects. In the illustrated embodiment, the optical elements are positioned in two parallel paths to generate a left view and a right view. Alternative embodiments may include optical paths that are folded, deflected or otherwise not parallel.
• The illustrated paths correspond to a human's visual system such that the left view and right view, as displayed on a stereoscopic display, appear to be separated by a distance that creates a convergence angle of roughly 6 degrees, which is comparable to the convergence angle for an adult human's eyes viewing an object at approximately 4 feet away, thereby resulting in stereopsis. In some embodiments, image data generated from the left view and right view are combined together on the display monitor(s)512 and514 to generate a stereoscopic image of a target site or scene. Alternative embodiments comprise other stereoscopic displays where the left view is presented to only the left eye of a viewer and the corresponding right view is presented to only the right eye. In exemplary embodiments used to adjust and verify proper alignment and calibration, both views are displayed overlaid to both eyes.
• A stereoscopic view is superior to a monoscopic view because it mimics the human visual system much more closely. A stereoscopic view provides depth perception, distance perception, and relative size perception to provide a realistic view of a target surgical site to a surgeon. For procedures such as retinal surgery, stereoscopic views are vital because surgical movements and forces are so small that the surgeon cannot feel them. Providing a stereoscopic view helps a surgeon's brain magnify tactile feel when the brain senses even minor movements while perceiving depth.
• FIG. 7 shows a side view of the examplestereoscopic visualization camera300 with thehousing302 being transparent to expose the optical elements.FIG. 8 shows a diagram illustrative of an optical path provided by the optical elements shown inFIG. 7. As shown inFIG. 8, the optical path includes a right optical path and a left optical path. The optical paths inFIG. 8 are shown from a perspective of facing a forward direction and looking down at thestereoscopic visualization camera300. From this view, the left optical path appear on the right side ofFIG. 8 while the right optical path is shown on the left side.
• The optical elements shown inFIG. 7 are part of the left optical path. It should be appreciated that the right optical path inFIG. 7 is generally identical to the left optical path regarding relation location and arrangement of optical elements. As mentioned above, the interpupillary distance between a center of the optical paths is between 58 to 70 mm, which may be scaled to 10 to 25 mm. Each of the optical elements comprise lenses having certain diameters (e.g., between 2 mm and 29 mm). Accordingly, a distance between the optical elements themselves is between 1 to 23 mm, preferably around 10 mm.
• The examplestereoscopic visualization camera300 is configured to acquire images of a target site700 (also referred to as a scene or field-of-view (“FOV”) or target surgical site). Thetarget site700 includes an anatomical location on a patient. Thetarget site700 may also include laboratory biological samples, calibration slides/templates, etc. Images from thetarget site700 are received at thestereoscopic visualization camera300 via a mainobjective assembly702, which includes the front working distance lens408 (shown inFIG. 4) and a rearworking distance lens704.
A. Example Main Objective Assembly
• The example mainobjective assembly702 may include any type of refractive assembly or reflective assembly.FIG. 7 shows theobjective assembly702 as an achromatic refractive assembly with the frontworking distance lens408 being stationary and the rearworking distance lens704 being movable along the z-axis. The frontworking distance lens408 may comprise a plano convex (“PCX”) lens and/or a meniscus lens. The rearworking distance lens704 may comprise an achromatic lens. In examples where the mainobjective assembly702 includes an achromatic refractive assembly, the frontworking distance lens408 may include a hemispherical lens and/or a meniscus lens. In addition, the rearworking distance lens704 may include an achromatic doublet lens, an achromatic doublet group of lenses, and/or an achromatic triplet lens.
• The magnification of the mainobjective assembly702 is between 6× to 20×. In some instances, the magnification of the mainobjective assembly702 may vary slightly based on a working distance. For example, the mainobjective assembly702 may have a magnification of 8.9× for a 200 mm working distance and a magnification of 8.75× for a 450 mm working distance.
• The example rearworking distance lens704 is configured to be movable with respect to the frontworking distance lens408 to change a spacing therebetween. The spacing between thelenses408 and704 determines the overall front focal length of the mainobjective assembly702, and accordingly the location of a focal plane. In some embodiments, the focal length is the distance between thelenses408 and704 plus one-half the thickness of the frontworking distance lens408.
• Together, the frontworking distance lens408 and the rearworking distance lens704 are configured to provide an infinite conjugate image for providing an optimal focus for downstream optical image sensors. In other words, an object located exactly at the focal plane of thetarget site700 will have its image projected at a distance of infinity, thereby being infinity-coupled at a provided working distance. Generally, the object appears in focus for a certain distance along the optical path from the focal plane. However, past the certain threshold distance, the object begins to appear fuzzy or out of focus.
• FIG. 7shows working distance706, which is the distance between an outer surface of the frontworking distance lens408 and to the focal plane of thetarget site700. The workingdistance706 may correspond to an angular field-of-view, where a longer working distance results in a wider field-of-view or larger viewable area. The workingdistance706 accordingly sets a plane of the target site or scene that is in focus. In the illustrated example, the workingdistance706 is adjustable from 200 to 450 mm by moving the rearworking distance lens704. In an example, the field-of-view can be adjusted between 20 mm×14 mm to 200 mm×140 mm using upstream zooming lenses when the working distance is 450 mm.
• The mainobjective assembly702 shown inFIGS. 7 and 8 provides an image of thetarget site700 for both the left and right optical paths. This means that the width of thelenses408 and704 should be at least as wide as the left and right optical paths. In alternative embodiments, the mainobjective assembly702 may include separate left and right frontworking distance lenses408 and separate left and right rearworking distance lens704. The width of each pair of the separate working distance lenses may be between ¼ to ½ of the width of thelenses408 and704 shown inFIGS. 7 and 8. Further, each of the rearworking distance lenses704 may be independently adjustable.
• In some embodiments, the mainobjective assembly702 may be replaceable. For example, different main objective assemblies may be added to change a working distance range, a magnification, a numerical aperture, and/or refraction/reflection type. In these embodiments, thestereoscopic visualization camera300 may change positioning of downstream optical elements, properties of optical image sensors, and/or parameters of image processing based on which main objective assembly is installed. An operator may specify which main objective assembly is installed in thestereoscopic visualization camera300 using one of the controls305 ofFIG. 3 and/or a user input device.
B. Example Lighting Sources
• To illuminate thetarget site700, the examplestereoscopic visualization camera300 includes one or more lighting sources.FIGS. 7 and 8 show three lighting sources including a visiblelight source708a, a near-infrared (“NIR”)light source708b, and a near-ultraviolet (“NUV”)light source708c. In other examples, thestereoscopic visualization camera300 may include additional or fewer (or no) light sources. For instance, the NIR and NUV light sources may be omitted. The example light sources708 are configured to generate light, which is projected to thetarget scene700. The generated light interacts and reflects off the target scene, with some of the light being reflected to the mainobjective assembly702. Other examples may include external light sources or ambient light from the environment.
• The example visiblelight source708ais configured to output light in the human-visible part of the light spectrum in addition to some light with wavelengths outside the visible region. The NIRlight source708bis configured to output light that is primarily at wavelengths slightly past the red part of the visible spectrum, which is also referred to as “near-infrared.” The NUVlight source708cis configured to output light that is primarily at wavelengths in the blue part of the visible spectrum, which is referred to as “near-ultraviolet.” The light spectra output by the light sources708 is controlled by respective controllers, described below. A brightness of light emitted by the light sources708 may be controlled by a switching rate and/or applied voltage waveform.
• FIGS. 7 and 8 illustrate that the visiblelight source708aand the NIRlight source708bare provided directly through the mainobjective assembly702 to thetarget site700. As shown inFIG. 8, visible light from the visiblelight source708apropagates alongvisible path710a. Additionally, NIR light from the NIRlight source708bpropagates alongNIR path710b. While thelight sources708aand708bare shown as being behind the main objective assembly702 (with respect to the target site700), in other examples thelight sources708aand708bmay be provided before the mainobjective assembly702. In one embodiment, thelight sources708aand708bmay be provided on an outside of thehousing302 and face toward thetarget site700. In yet other embodiments, the light sources708 may be provided separate from thestereoscopic visualization camera300 using, for example, a Koeher illumination setup and/or a darkfield illumination setup.
• In contrast to thelight sources708aand708b, NUV light from the NUVlight source708cis reflected by a deflecting element712 (e.g., a beamsplitter) to the mainobjective assembly702 using an epi-illumination setup. The deflectingelement712 may be coated or otherwise configured to reflect only light beyond the NUV wavelength range, thereby filtering NUV light. NUV light from the NUVlight source708cpropagates alongNUV path710c.
• In some embodiments, the NIR and NUVlight sources708band708cmay be used with excitation filters to further filter light that may not be blocked by filters (e.g., filter740). The filters may be placed in front of thelight sources708band708cbefore the mainobjective assembly702 and/or after the main objective assembly. The light from the NUV and NIRlight sources708band708c, after being filtered, comprises wavelengths that excite fluorescence in fluorescent sites914 (shown inFIG. 9) of an anatomical object. Further, the light from the NUV and NIRlight sources708band708c, after being filtered, may comprise wavelengths that are not in the same range as those being emitted by thefluorescent sites914.
• The projection of the light from light sources708 through the main objective assembly provides the benefit of changing the lighted field-of-view based on theworking distance706 and/or focal plane. Since the light passes through the mainobjective assembly702, the angle at which light is projected changes based on theworking distance706 and corresponds to the angular field-of-view. This configuration accordingly ensures the field-of-view is properly illuminated by the light sources708, regardless of working distance or magnification.
C. Example Deflecting Element
• Theexample deflecting element712 illustrated inFIGS. 7 and 8 is configured to transmit a certain wavelength of light from the NUVlight source708cto thetarget site700 through the mainobjective assembly702. The deflectingelement712 is also configured to reflect light received from thetarget site700 to downstream optical elements, including a front lens set714 for zooming and recording. In some embodiments, the deflectingelement712 may filter light received from thetarget site700 through the mainobjective assembly702 so that light of certain wavelengths reaches thefront lens set714.
• The deflectingelement712 may include any type of mirror or lens to reflect light in a specified direction. In an example, the deflectingelement712 includes a dichroic mirror or filter, which has different reflection and transmission characteristics at different wavelengths. Thestereoscopic visualization camera300 ofFIGS. 7 and 8 includes asingle deflecting element712, which provides light for both the right and left optical paths. In other examples, thecamera300 may include separate deflecting elements for each of the right and left optical paths. Further, a separate deflecting element may be provided for the NUVlight source708c.
• FIG. 9 shows a diagram of the deflectingelement712 ofFIGS. 7 and 8, according to an example embodiment of the present disclosure. For brevity, the mainobjective assembly702 is not shown. In this example, the deflectingelement712 includes twoparallel faces902 and904 for transmitting and reflecting light of certain wavelengths. The parallel faces902 and904 are set at a 45° angle with respect to the left and right optical paths (represented as path906). The 45° angle is selected since this angle causes reflected light to propagate at a 90° angle from the transmitted light, thereby providing optimal separation without causing the separated light to be detected in the downstreamfront lens set714. In other embodiments, the angle of the deflectingelement712 could be between 10 degrees and 80 degrees without unintentionally propagating light of unwanted wavelengths.
• The example NUVlight source708cis located behind the deflecting element712 (with respect to the target site700). Light from thelight source708cpropagates alongpath908 and contacts the deflectingelement712. NUV light around the primary wavelength range of the NUVlight source708cis transmitted through the deflectingelement712 alongpath910 to thetarget site700. Light from the NUVlight source708cthat has a wavelength above (and below) the primary wavelength range of the NUVlight source708cis reflected alongpath912 to a light sink or unused region of thehousing302.
• When the NUV light reaches thetarget site700, it is absorbed by one or morefluorescent sites914 of an anatomical object. In some instances, the anatomical object may have been injected with a contrast agent configured to absorb NUV light and emit light with a different primary wavelength. In other instances, the anatomical object may naturally absorb NUV light and emit light with a different primary wavelength. At least some of the light reflected or emitted by thefluorescent site914 propagates alongpath916 until it contacts the deflectingelement712. Most of the light reflects off thesurface904 alongpath906 to thefront lens set714. A portion of the light, including NUV light around the primary wavelength range of the NUVlight source708cis transmitted through the deflectingelement712 alongpath918 to a light sink or unused region of thehousing302. The deflectingelement712 shown inFIG. 9 accordingly enables optical stimulation of a fluorescent agent at thetarget site700 with one region of the spectrum while blocking much of the stimulating light from travelling to the downstreamfront lens set714.
• It should be appreciated that the reflectivity and transmissivity characteristics of the deflectingelement712 can be changed to meet other light spectrum requirements. In some instances, thehousing302 may include a slot that enables the deflectingelement712 and/or the NUVlight source708cto be replaced based on the desired light reflectivity and transmissivity characteristics. It should also be appreciated that a first path internal to the deflectingelement712 betweenpath908 andpath910 and a second path internal to the deflectingelement712 betweenpath916 andpath918 are each angled to represent schematically the refraction of the light as it travels between air and the interior of the deflectingelement712. The angles shown are not meant to represent actual reflection angles.
D. Example Zoom Lenses
• The examplestereoscopic visualization camera300 ofFIGS. 7 and 8 includes one or more zoom lens to change a focal length and angle of view of thetarget site700 to provide zoom magnification. In the illustrated example, the zoom lens includes the front lens set714, azoom lens assembly716, and a lens barrel set718. It should be appreciated that in other embodiments, the front lens set714 and/or the lens barrel set718 may be omitted. Alternatively, the zoom lens may include additional lens to provide further magnification and/or image resolution.
• The front lens set714 includes a rightfront lens720 for the right optical path and a leftfront lens722 for the left optical path. Thelenses720 and722 may each include a positive converging lens to direct light from the deflectingelement712 to respective lenses in thezoom lens assembly716. A lateral position of thelenses720 and722 accordingly defines a beam from the mainobjective assembly702 and the deflectingelement712 that is propagated to thezoom lens assembly716.
• One or both of thelenses720 and722 may be adjustable radially to match optical axes of the left and right optical paths. In other words, one or both of thelenses720 and722 may be moved left-right and/or up-down in a plane incident to the optical path. In some embodiments, one or more of thelenses720 and722 may be rotated or tilted to reduce or eliminate image optical defects and/or spurious parallax. Moving either or both of thelenses720 and722 during zooming may cause the zoom repeat point (“ZRP”) for each optical path to appear to remain stationary to a user. In addition to radial movement, one or both of thefront lenses720 and722 may be moved axially (along the respective optical path) to match magnifications of the optical paths.
• The examplezoom lens assembly716 forms an afocal zoom system for changing the size of a field-of-view (e.g., a linear field-of-view) by changing a size of the light beam propagated to the lens barrel set718. Thezoom lens assembly716 includes a front zoom lens set724 with a rightfront zoom lens726 and a leftfront zoom lens728. Thezoom lens assembly716 also includes a rear zoom lens set730 with a rightrear zoom lens732 and a leftrear zoom lens734. Thefront zoom lenses726 and728 may be positive converging lenses while therear zoom lenses732 and734 include negative diverging lenses.
• The size of an image beam for each of the left and right optical paths is determined based on a distance between thefront zoom lenses726 and728, therear zoom lenses732 and734 and the lens barrel set718. Generally, the size of the optical paths reduces as therear zoom lenses732 and734 move toward the lens barrel set718 (along the respective optical paths), thereby decreasing magnification. In addition, thefront zoom lenses726 and728 may also move toward (or away from) the lens barrel set718 (such as in a parabolic arc), as therear zoom lenses732 and734 move toward the lens barrel set718, to maintain the location of the focal plane on thetarget site700, thereby maintaining focus.
• Thefront zoom lenses726 and728 may be included within a first carrier (e.g., the front zoom set724) while therear zoom lenses732 and724 are included within a second carrier (e.g., the rear zoom set730). Each of thecarriers724 and730 may be moved on tracks (or rails) along the optical paths such that left and right magnification changes concurrently. In this embodiment, any slight differences in magnification between the left and right optical paths may be corrected by moving the rightfront lens720 and/or the leftfront lens722. Additionally or alternatively, aright lens barrel736 and/or aleft lens barrel738 of the lens barrel set718 may be moved axially.
• In alternative embodiments, the rightfront zoom lens726 may be moved axially separately from the leftfront zoom lens728. In addition, the rightrear zoom lens732 may be moved axially separately from the leftrear zoom lens734. Separate movement may enable small magnification differences to be corrected by thezoom lens assembly716, especially when the front lens set714 and the lens barrel set718 are stationary along the optical paths. Further, in some embodiments, the rightfront zoom lens726 and/or the leftfront zoom lens728 may be radially and/or rotationally adjustable (and/or tilted) to maintain an apparent location of a ZRP in the optical path. Additionally or alternatively, the rightrear zoom lens732 and/or the leftrear zoom lens734 may be radially and/or rotationally adjustable (and/or tilted) to maintain an apparent location of a ZRP in the optical path.
• The example lens barrel set718 includes theright lens barrel736 and theleft lens barrel738, which are part of the afocal zoom system in addition with thezoom lens assembly716. Thelenses736 and738 may include positive converging lenses configured to straighten or focus a light beam from thezoom lens assembly716. In other words, thelenses736 and738 focus the infinity-coupled output of thezoom lens assembly716.
• In some examples, the lens barrel set718 is fixed radially and axially within thehousing302. In other examples, the lens barrel set718 may be movable axially along the optical path to provide increased magnification. Additionally or alternatively, each of thelenses736 and738 may be radially and/or rotationally adjustable (and/or tilted) to, for example, correct for differences in optical properties (from manufacturing or natural glass deviations) between the left and right lenses of the front lens set714, the front zoom lens set724, and/or the rear zoom lens set730.
• Altogether, the example front lens set714, thezoom lens assembly716, and the lens barrel set718 are configured to achieve an optical zoom between 5× to about 20×, preferably at a zoom level that has diffraction-limited resolution. In some embodiments, the front lens set714, thezoom lens assembly716, and the lens barrel set718 may provide higher zoom ranges (e.g., 25× to 100×) if image quality can be compromised. In these embodiments, thestereoscopic visualization camera300 may output a message to an operator indicative that a selected optical range is outside of an optical range and subject to a reduction in image quality.
• In some embodiments, the lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the mainobjective assembly702 may each be constructed as a doublet from multiple optical sub-elements using materials that balance each other's optical distortion parameters. The doublet construction reduces chromatic aberrations and optical aberrations. For example, the frontworking distance lens408 and the rearworking distance lens702 may each be constructed as a doublet. In another example, thefront lenses720 and722, thefront zoom lenses726 and728, therear zoom lenses732 and734, and the lens barrels736 and738 may each comprise a doublet lens.
• In yet further embodiments, the lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the mainobjective assembly702 may be tuned differently and/or have different properties to provide two parallel optical paths with different capabilities. For example, right lenses inzoom lens assembly716 may be selected to provide5X to10X optical zoom for the right optical path while left lenses in thezoom lens assembly716 are selected to provide15X to20X optical zoom for the left optical path. Such a configuration may enable two different magnifications to be shown at the same time and/or on the same screen, though in a monoscopic view.
E. Example Filter
• The examplestereoscopic visualization camera300 ofFIGS. 7 and 8 includes one or more optical filters740 (or filter assemblies) to selectively transmit desired wavelengths of light.FIG. 8 shows that asingle filter740 may be applied to the right and left optical paths. In other examples, each of the optical paths may have a separate filter. The inclusion of separate filters enables, for example, different wavelengths of light to be filtered from the left and right optical paths at the same time, which enables, for example, fluorescent images to be displayed in conjunction with visible light images.
• FIG. 7 shows that thefilter740 includes a wheel that is rotated about its axis of rotation. In the illustrated embodiment, thefilter740 can accommodate three different optical filter pairs. However, in other embodiments, thefilter740 may include additional or fewer filter pairs. Generally, light received at thefilter740 from thetarget site700 includes a broad spectrum of wavelengths. The lenses of the mainobjective assembly702, the front lens set714, thezoom lens assembly716, and the lens barrel set718 are configured to pass a relatively wide bandwidth of light including wavelengths of interest to an operator and undesirable wavelengths. In addition, downstream optical image sensors are sensitive to certain wavelengths. Theexample filter740 accordingly passes and blocks certain portions of the light spectrum to achieve different desirable features.
• As a wheel, thefilter740 comprises a mechanical device capable of changing positions at about four times per second. In other embodiments, thefilter740 may include a digital micro-mirror, which can change a light path's direction at video frame rates such as 60 times per second. In these other embodiments, each of the left and right optical paths would include a micro-mirror. The left and right micro-mirror may have synchronized or simultaneous switching.
• In some embodiments, thefilter740 may be synchronized to the light sources708 to realize “time-interleaved” multispectral imaging. For example, thefilter740 may include an infrared cut filter, near-infrared bandpass filter, and near-ultraviolet cut filter. The different filter types are selected to work with different spectra of the light sources708 and the reflectivity and transmissivity characteristics of the deflectingelement712 to pass certain desired wavelengths of light at predetermined times.
• In one mode, thefilter740 and the light sources708 are configured to provide a visible light mode. In this mode, the visiblelight source708atransmits light from the visible region onto thetarget site700, some of which is reflected to the mainobjective assembly702. The reflected light may include some light beyond the visible spectrum, which may affect optical image sensors. The visible light is reflected by the deflectingelement712 and passes through the front lens set714, thezoom lens assembly716, and the lens barrel set718. In this example, thefilter740 is configured to apply the infrared-cut filter or the near-ultraviolet cut filter to the optical paths to remove light outside the visible spectrum such that light only in the visible spectrum passes through to a finaloptical set742 and anoptical image sensor744.
• In another mode,filter740 and the light sources708 are configured to provide fluorescence light of a narrow wavelength to theoptical sensor744. In this mode, the NUVlight source708ctransmits light from the deep-blue region of the spectrum to thetarget site700. The deflectingelement712 allows the desired light of the deep-blue region to pass through while reflecting undesired light. The deep-blue light interacts with thetarget site700 such that fluorescence light is emitted. In some examples, δ-Aminolaevulinic acid (“5ala”) and/or Protoporphyrin IX is applied to thetarget site700 to cause fluorescence light to be emitted when deep-blue light is received. The mainobjective assembly702 receives the fluorescence light in addition to reflected deep-blue light and some visible light. The deep-blue light passes through the deflectingelement712 out of the right and left optical paths. Thus, only the visible light and fluorescence light pass through the front lens set714, thezoom lens assembly716, and the lens barrel set718. In this example, thefilter740 is configured to apply the near-ultraviolet cut filter to the optical paths to remove light outside the desired fluorescence spectrum including visible light and any remaining NUV deep-blue light. Accordingly, only fluorescence light of a narrow wavelength reaches theoptical image sensor744, which enables the fluorescence light to be more easily detected and distinguished based on relative intensity.
• In yet another mode, thefilter740 and the light sources708 are configured to provide indocyanine green (“ICG”) fluorescence light to theoptical sensor744. In this mode, the NIVlight source708btransmits light in the far-red region (which is also considered near-infrared) of the visible spectrum to thetarget site700. In addition, the visiblelight source708atransmits visible light to thetarget scene700. The visible light and far-red light are absorbed by material with ICG at the target site, which then emits a highly stimulated fluorescence light in the further-red region. The mainobjective assembly702 receives the fluorescence light in addition to reflected NIR light and visible light. The light is reflected by the deflectingelement712 to the front lens set714, thezoom lens assembly716, and the lens barrel set718. In this example, thefilter740 is configured to apply the near-infrared bandpass filter to the optical paths to remove light outside the desired fluorescence spectrum including visible light and at least some of the NIR light. Accordingly, only fluorescence light in the further-red region reaches theoptical image sensor744, which enables the fluorescence light to be more easily detected and distinguished based on relatively intensity.

• TABLE 1
  Light		Light Transmitted to
  Source	Filter	Image Sensors
  Visible	Infrared Cut Filter,	Visible Light
  	Near-Ultraviolet Cut Filter
  NUV	Near-Ultraviolet Cut Filter	Blue Visible and
  		NIR Light
  NIR and	Near-Infrared Bandpass	Further-Red
  Visible	Filter	Fluorescence

• Table 1 above shows a summary of the different possible combinations of lights sources and filters for causing light of a certain desired wavelength to reach the opticallight sensor744. It should be appreciated that other types of filters and/or light sources may be used to further increase the different types of light received at theimage sensor744. For instance, bandpass filters configured to pass light of a narrow wavelength may be used to correspond to certain biological stains or contrasts applied to thetarget site700. In some examples, thefilter740 may include a cascade or more than one filter to enable light from two different ranges to be filtered. For example, afirst filter740 may apply an infrared cut filter and a near-ultraviolet cut filter such that only visible light of a desired wavelength range passes to theoptical sensor744.
• In other embodiments,separate filters740 may be used for the left and right optical paths. For example, a right filter may include an infrared cut filter while a left filter includes a near-infrared pass filter. Such a configuration enables viewing of thetarget site700 in visible wavelengths simultaneously with IGC green fluorescence wavelengths. In another example, a right filter may include an infrared cut filter while a left filter includes a near-ultraviolet cut filter. In this configuration, thetarget site700 may be shown in visible light simultaneously with 5ALA fluorescence light. In these other embodiments, the right and left image streams may still be combined into a stereoscopic view that provides a fluorescence view of certain anatomical structures combined with a view of thetarget site700 in visible light.
F. Example Final Optical Element Set
• The examplestereoscopic visualization camera300 ofFIGS. 7 and 8 includes the final optical element set742 to focus light received from thefilter740 onto theoptical image sensor744. The final optical element set742 includes a right finaloptical element745 and a left finaloptical element747, which may each comprise a positive converging lens. In addition to focusing light, theoptical elements745 and747 may be configured to correct minor aberrations in the right and left optical paths prior to the light reaching theoptical image sensor744. In some examples, thelenses745 and747 may be movable radially and/or axially to correct magnification and/or focusing aberrations caused by the front lens set714, thezoom lens assembly716, and the lens barrel set718. In an example, the left finaloptical element747 may be moved radially while the right finaloptical element745 is fixed to remove ZRP movement during magnification changes.
G. Example Image Sensors
• The examplestereoscopic visualization camera300 ofFIGS. 7 and 8 includes theimage sensor744 to acquire and/or record incident light that is received from the final optical element set742. Theimages sensor744 includes a rightoptical image sensor746 to acquire and/or record light propagating along the right optical path and a leftoptical image sensor748 to acquire and/or record light propagating along the left optical path. Each of the left and rightoptical image sensors746 and748 include, for example, complementary metal-oxide-semiconductor (“CMOS”) sensing elements, N-type metal-oxide-semiconductor (“NMOS”), and/or semiconductor charge-coupled device (“CCD”) sensing elements. In some embodiments, the left and rightoptical sensors746 and748 are identical and/or have the same properties. In other embodiments, the left and rightoptical sensors746 and748 include different sensing elements and/or properties to provide varying capability. For example, the right optical image sensor746 (using a first color filter array) may be configured to be more sensitive to blue fluorescence light while the left optical image sensor748 (using a second color filter array) is configured to be more sensitive to visible light.
• FIG. 10 shows an example of the rightoptical image sensor746 and the leftoptical image sensor748 of theimage sensor744, according to an example embodiment of the present disclosure. The rightoptical image sensor746 includes a first two-dimensional grid ormatrix1002 of light-sensing elements (e.g., pixels). In addition, the leftoptical image sensor748 includes a second two-dimensional pixel grid1004 of light-sensing elements. Each of the pixels includes a filter that enables only light of a certain wavelength to pass, thereby contacting an underlying light detector. Filters for different colors are spread across thesensors746 and748 to provide light detection for all wavelengths across grids. The light detector may be sensitive to visible light, as well as additional ranges that are above and below the visible spectrum.
• The light-sensing elements of thegrids1002 and1004 are configured to record a range of wavelengths of light as a representation of thetarget site700 that is in the field-of-view. Light incident on a light-sensing element causes an electrical change to accumulate. The electrical charge is read to determine an amount of light being received at the sensing element. In addition, since the filter characteristics of the sensing element are known to within manufacturing tolerances, the range of wavelengths of the received light is known. The representation of thetarget site700 is directed onto the light-sensing elements such that thegrids1002 and1004 for the respectiveoptical image sensors746 and748 sample thetarget site700 spatially. The resolution of the spatial sampling is a parameter that affects image quality and parity.
• The number of pixels shown in thepixel grids1002 and1004 inFIG. 10 is not representative of the number of actual pixels in theoptical image sensors746 and748. Instead, the sensors typically have a resolution between 1280×720 pixels and 8500×4500 pixels, preferably around 2048×1560 pixels. However, not all pixels of thegrids1002 and1004 are selected for image transmission. Instead, a subset or pixel set of thegrids1002 and1004 are selected for transmission. For example, inFIG. 10, pixel set1006 is selected from thepixel grid1002 for transmission as a right image andpixel set1008 is selected frompixel grid1004 for transmission as a left image. As illustrated, thepixel set1006 does not need to be located in the same location as thepixel set1008 in relation torespective pixel grids1002 and1004. The separate control of the pixel sets1006 and1008 enables left and right images to be aligned and/or corrected for image defects and/or spurious parallax such as moving ZRPs.
• Selection of a pixel set from a pixel grid enables a portion of the pixel grid to be selected to compensate for image defects/spurious parallax and/or to more align the right and left optical images. In other words, the pixel set may be moved or adjusted (in real-time) with respect to the pixel grid to improve image quality by reducing or eliminating spurious parallax. Alternatively, either or both of the left and right views of the stereoscopic image can be moved virtually in the image processing pipeline (for example during rendering of the views for display) to accomplish the same effect. Rotational misalignment of the sensors can also be corrected virtually. A pixel set may also be moved across a pixel grid during use to provide an appearance of panning the field-of-view. In an example, a pixel set or window of 1920×1080 pixels may be selected from a pixel grid having 2048×1560 pixels. The location of the pixel window or set may be controlled by software/firmware and be moved during setup and/or use. The resolution of theoptical image sensors746 and748 is accordingly specified based on a number of pixels in the length and width directions of the pixel set or window.
1. Color Sensing with the Example Image Sensors
• As mentioned above, theoptical sensing elements746 and748 include pixels with different filters to detect certain colors of light. For instance, some pixels are covered with filters that pass predominantly red light, some are covered with filters that pass predominantly green light, and some are covered with filters that pass predominantly blue light. In some embodiments, a Bayer pattern is applied to thepixel grids1002 and1004. However, it should be appreciated that in other embodiments, a different color pattern may be used that is optimized for certain wavelengths of light. For example, a green filter in each sensing region may be replaced with a broadband filter or a near-infrared filter, thereby extending the sensing spectrum.
• The Bayer pattern is implemented by grouping two rows by two columns of pixels and covering one with a red filter, one with a blue filter, and two with a green filter, each in a checkerboard pattern. Thus the resolution of red and blue are each one quarter of the whole sensing region of interest while green resolution is half that of the whole sensing region of interest.
• Green may be assigned to half the sensing region to cause theoptical image sensors746 and748 to operate as a luminance sensor and mimic the human visual system. In addition, red and blue mimic chrominance sensors of the human visual system, but are not as critical as green sensing. Once an amount of red, green, and blue are determined for a certain region, other colors in the visible spectrum are determined by averaging the red, green, and blue values, as discussed in conjunction withde-Bayer program1580aofFIG. 16 discussed below.
• In some embodiments, theoptical image sensors746 and748 may use stacked components to sense color rather than filters. For example, sensing elements may include red, green and blue sensing components stacked vertically inside a pixel's area. In another example, prisms split incident light into components using specially coated beamsplitters one or more times (typically at least two times resulting in three component colors, known as “3-chip”) with sensing elements placed in each of the split beams' paths. Other sensor types use a different pattern such as replacing one of the green filters with a broadband filter or a near-infrared filter, thereby extending the sensing possibilities of the digital surgical microscope.
2. Sensing Light Outside the Visible Range with the Example Image Sensors
• The example sensing element filters of theoptical image sensors746 and748 are configured to also pass near-infrared light in a range that the sensing element can detect. This enables theoptical image sensors746 and748 to detect at least some light outside of the visible range. Such sensitivity may decrease image quality in the visible part of the spectrum because it “washes out” the image, reducing contrast in many types of scenes and negatively affecting the color quality. As a result, thefilter740 may use the infrared cut filter to block near infrared wavelengths while passing the visible wavelengths to theoptical image sensors746 and748.
• However, such near-infrared sensitivity may be desirable. For example, a fluorescent agent, such ICG, can be introduced to thetarget site700. ICG becomes excited or activated with visible or other wavelengths or light and emits fluorescence light in the near infrared range. As mentioned above, the NIRlight source708bprovides NIR light and the visiblelight source708aprovides visible light to excite agents with ICG. Emitted light is further along the red spectrum, which may be passed through thefilter740 using a near-infrared bandpass or high-pass filter. The light from the red spectrum then is detected by theoptical image sensors746 and748. By matching the spectral characteristics of thefilter740 to the expected behaviors of the light source708 and the fluorescent agent, the agent and the biological structures, such as blood that contain the agent, can be differentiated at thetarget site700 from other structures that do not contain the agent.
• Note that in this example, the NIRlight source708bhas a different primary wavelength from the near-infrared filter in thefilter740. Specifically, the NIRlight source708bhas a primary wavelength around 780 nanometers (“nm”) (around which the majority of the light's output spectrum exists). In contrast, the near-infrared filter of thefilter740 transmits light at wavelengths in a range of approximately 810 nm to 910 nm. The light from the NIRlight source708band light passed through thefilter740 are both “near-infrared” wavelengths. However, the light wavelengths are separated so that the examplestereoscopic visualization camera300 can stimulate with the light source708 and detect with theoptical image sensor744 while filtering the stimulation light. This configuration accordingly enables the use of fluorescent agents.
• In another embodiment, agents can be excited in the blue, violet, and near-ultraviolet region and fluoresce light in the red region. An example of such an agent includes porphyrin accumulation in malignant gliomas caused by the introduction of 5ALA. In this example, it is necessary to filter out the blue light while passing the remainder of the spectrum. A near-ultraviolet cut filter is used for this situation. As in the case with “near-infrared” discussed above, the NUVlight source708chas a different primary wavelength from the near-ultraviolet cut filter in thefilter740.
H. Example Lens Carrier
• Section IV(D) above mentions that at least some of the lenses of the front lens set714, thezoom lens assembly716, and/or the lens barrel set718 may move in one or more carriers along rails. For example, the front zoom lens set724 may comprise a carrier that movesfront zoom lens726 and728 together axially.
• FIGS. 11 and 12 show diagrams of example carriers, according to example embodiments of the present disclosure. InFIG. 11,carrier724 includes the rightfront zoom lens726 and the leftfront zoom lens728 within asupport structure1102. Thecarrier724 includes arail holder1104 configured to moveably connect torail1106. A force ‘F’ is applied to anactuation section1108 to cause thecarrier724 to move along therail1106. The force ‘F’ may be applied by a leadscrew or other linear actuation device. As illustrated inFIG. 11, the force ‘F’ is applied at an offset of thecarrier724. Friction between therail1106 and thecarrier724 generates a moment My that causes thesupport structure1102 to move slightly around the Y-axis shown inFIG. 11. This slight movement may cause the rightfront zoom lens726 and the leftfront zoom lens728 to shift slightly in opposite directions causing spurious parallax, which is an error in a parallax between views of a stereoscopic image.
• FIG. 12 shows another example of thecarrier724. In this example, force ‘F’ is applied symmetrically atcenter structure1202, which is connected to therail holder1104 and thesupport structure1102. The force ‘F’ generates a moment Mx that causes thecarrier724 to rotate or move slightly around the X-axis shown inFIG. 12. The rotational movement causes the rightfront zoom lens726 and the leftfront zoom lens728 to shift in the same direction by the same degree of movement, thereby reducing (or eliminating) the onset of spurious parallax.
• WhileFIGS. 11 and 12show lenses726 and728 within one carrier, in other embodiments thelenses726 and728 may each be within a carrier. In these examples, each lens would be on a separate track or rail. Separate leadscrews may be provided for each of the lenses to provide independent axial movement along the respective optical path.
I. Example Flexure
• Section IV(D) above mentions that at least some of the lenses of the front lens set714, thezoom lens assembly716, and/or the lens barrel set718 may be moved radially, rotated, and/or tilted. Additionally or alternatively, theoptical image sensors746 and748 may be moved axially and/or tilted with respect to their respective incident optical path. The axial and/or tilt movement may be provided by one or more flexures. In some examples, the flexures may be cascaded such that a first flexure provides motion in a first direction and separate flexure provides independent motion in a second direction. In another example, a first flexure provides tilt along a pitch axis and separate flexure provides tilt along a yaw axis.
• FIG. 13 shows a diagram of an exampledual flexure1300, according to an example embodiment of the present disclosure. Theflexure1300 illustrated inFIG. 13 is for theoptical image sensor744 and is configured to independently move the rightoptical image sensor746 and the leftoptical image sensor748 along their respective optical axis for purposes of final focusing. Theflexure1300 includes asupport beam1301 for connection to thehousing302 of the examplestereoscopic visualization camera300 and to provide a rigid base for actuation. Theflexure1300 also includes abeam1302 for each channel (e.g.,sensor746 and748) that is rigid in all directions except for the direction ofmotion1310. Thebeam1302 is connected to flexinghinges1303 that enable thebeam1302 to move in a direction ofmotion1310, a parallelogram translation in this example.
• Anactuator device1304 flexes thebeam1302 in the desired direction for a desired distance. Theactuator device1304 includes a push-screw1306 and apull screw1308, for each channel, which apply opposite forces to thebeam1302 causing the flexing hinges1303 to move. Thebeam1302 may be moved inward, for example, by turning the push-screw1306 to push on thebeam1302. Theflexure1300 illustrated inFIG. 13 is configured to independently move the rightoptical image sensor746 and the leftoptical image sensor748 axially along their optical axis.
• After thebeam1302 is flexed into a desired position, a locking mechanism is engaged to prevent further movement, thereby creating a rigid column. The locking mechanism includes the push-screw1306 and its respectiveconcentric pull screw1308, that when tightened, create large opposing forces that result in the rigid column of thebeam1302.
• While theoptical image sensors746 and748 are shown as being connected to thesame flexure1300, in other examples, the sensors may be connected to separate flexures. For example, returning toFIG. 8, the rightoptical image sensor746 is connected to flexure750 and the leftoptical image sensor748 is connected toflexure752. The use of theseparate flexures750 and752 enables theoptical image sensors746 and748 to be separately adjusted to, for example, align the left and right optical views and/or reduce or eliminate spurious parallax.
• In addition, whileFIG. 13 showsimage sensors746 and748 connected to theflexure1300, in other examples, the lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the final optical element set742 may be connected to alternative or additional flexures instead. In some instances, each of the right and left lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the final optical element set742 may be connected to aseparate flexure1300 to provide independent radial, rotational, and/or tilt adjustment.
• Theflexure1300 may provide motion resolution of less than a micron. As a result of the very fine motion adjustment, images from the right and left optical paths may have an alignment accuracy of several or even one pixel for a 4K display monitor. Such accuracy is viewed on eachdisplay512,514 by overlaying the left and right views and observing both views with both eyes, rather than stereoscopically.
• In some embodiments, theflexure1300 can include the flexure disclosed in U.S. Pat. No. 5,359,474, titled “SYSTEM FOR THE SUB-MICRON POSITIONING OF A READ/WRITE TRANSDUCER,” the entirety of which is incorporated herein by reference. In yet other embodiments, the lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the final optical element set742 may be stationary in a radial direction. Instead, a deflecting element (e.g., a mirror) with an adjustable deflection direction in an optical path may be used to steer the right and/or left optical paths to adjust alignment and/or spurious parallax. Additionally or alternatively, a tilt/shift lens may be provided in the optical path. For instance, a tilt of an optical axis may be controlled with an adjustable wedge lens. In further embodiments, lenses of the front lens set714, thezoom lens assembly716, the lens barrel set718, and/or the final optical element set742 may include dynamic lenses with parameters that can be changed electronically. For example, the lenses may include Varioptic liquid lenses produced by Invenios France SAS.
V. Example Processors of the Stereoscopic Visualization Camera
• The examplestereoscopic visualization camera300 is configured to record image data from the right and left optical paths and output the image data to the monitor(s)512 and/or514 for display as a stereoscopic image.FIG. 14 shows a diagram of modules of the examplestereoscopic visualization camera300 for acquiring and processing image data, according to an example embodiment of the present disclosure. It should be appreciated that the modules are illustrative of operations, methods, algorithms, routines, and/or steps performed by certain hardware, controllers, processors, drivers, and/or interfaces. In other embodiments, the modules may be combined, further partitioned, and/or removed. Further, one or more of the modules (or portions of a module) may be provided external to thestereoscopic visualization camera300 such as in a remote server, computer, and/or distributed computing environment.
• In the illustrated embodiment ofFIG. 14, thecomponents408,702 to750, and1300 inFIGS. 7 to 13 are collectively referred to asoptical elements1402. The optical elements1402 (specifically theoptical image sensors746 and748) are communicatively coupled to animage capture module1404 and a motor andlighting module1406. Theimage capture module1404 is communicatively coupled to aninformation processor module1408, which may be communicatively coupled to an externally locateduser input device1410 and one or more display monitors512 and/or514.
• The exampleimage capture module1404 is configured to receive image data from theoptical image sensors746 and748. In addition, theimage capture module1404 may define the pixel sets1006 and1008 within therespective pixel grids1002 and1004. Theimage capture module1404 may also specify image recording properties, such as frame rate and exposure time.
• The example motor andlighting module1406 is configured to control one or more motors (or actuators) to change a radial, axial, and/or tilt position of one or more of theoptical elements1402. For instance, a motor or actuator may turn a drive screw to move thecarrier724 along thetrack1106, as shown inFIGS. 11 and 12. A motor or actuator may also turn the push-screw1306 and/or thepull screw1308 of theflexure1300 ofFIG. 13 to adjust a radial, axial, or tilt position of a lens and/or optical image sensor. The motor andlighting module1406 may also include drivers for controlling the light sources708.
• The exampleinformation processor module1408 is configured to process image data for display. For instance, theinformation processor module1408 may provide color correction to image data, filter defects from the image data, and/or render image data for stereoscopic display. Theinformation processor module1408 may also perform one or more calibration routines to calibrate thestereoscopic visualization camera300 by providing instructions to theimage capture module1404 and/or the motor andlighting module1406 to perform specified adjustments to the optical elements. Theinformation processor module1408 may further determine and provide in real-time instructions to theimage capture module1404 and/or the motor andlighting module1406 to improve image alignment and/or reduce spurious parallax.
• The exampleuser input device1410 may include a computer to provide instructions for changing operation of thestereoscopic visualization camera300. Theuser input device1410 may also include controls for selecting parameters and/or features of thestereoscopic visualization camera300. In an embodiment, theuser input device1410 includes the control arms304 ofFIG. 3. Theuser input device1410 may be hardwired to theinformation processor module1408. Additionally or alternatively, theuser input device1410 is wirelessly or optically communicatively coupled to theinformation processor module1408.
• The example display monitors512 and514 include, for example, televisions and/or computer monitors configured to provide a three-dimensional viewing experience. For example, the display monitors may include the LG® 55LW5600 television. Alternatively, the display monitors512 and514 may include a laptop screen, tablet screen, a smartphone screen, smart-eyewear, a projector, a holographic display, etc.
• The sections that follow describe theimage capture module1404, the motor andlighting module1406, and theinformation processor module1408 in more detail.
A. Example Image Capture Module
• FIG. 15 shows a diagram of theimage capture module1404, according to an example embodiment of the present disclosure. The exampleimage capture module1404 includes animage sensor controller1502, which includes aprocessor1504, amemory1506, and acommunications interface1508. Theprocessor1504, thememory1506, and thecommunications interface1508 may be communicatively coupled together via an imagesensor controller bus1512.
• Theprocessor1504 is programmable with one ormore programs1510 that are persistently stored within thememory1506. Theprograms1510 include machine readable instructions, which when executed, cause theprocessor1504 to perform one or more steps, routines, algorithms, etc. In some embodiments, theprograms1510 may be transmitted to thememory1506 from theinformation processor module1408 and/or from theuser input device1410. In other examples, theprograms1510 may be transmitted to theprocessor1504 directly from theinformation processor module1408 and/or from theuser input device1410.
• The exampleimage sensor controller1502 is communicatively coupled to the rightoptical image sensor746 and the leftoptical image sensor748 of theoptical elements1402. Theimage sensor controller1502 is configured to provide power to theoptical image sensors746 and748 in addition to sending timing control data and/or programming data. In addition, theimage sensor controller1502 is configured to receive image and/or diagnostic data from theoptical image sensors746 and748.
• Each of theoptical image sensors746 and748 contains programmable registers to control certain parameters and/or characteristics. One or more of the registers may specify a location of the pixel sets1006 and1008 within therespective pixel grids1002 and1004 ofFIG. 10. The registers may store a value of a starting location with respect to an origin point or edge point of thepixel grids1002 and1004. The registers may also specify a width and height of the pixel sets1006 and1008 to define a rectangular region of interest. Theimage sensor controller1502 is configured to read pixel data for pixels that are within the specified pixel sets1006 and1008. In some embodiments, the registers of theoptical image sensors746 and748 may facilitate the designation of pixel sets of other shapes, such as circles, ovals, triangles, etc. Additionally or alternatively, the registers of theoptical image sensors746 and748 may enable multiple pixel sets to be specified simultaneously for each of thepixel grids1002 and1004.
• A light-sensing portion of the pixels of thepixel grids1002 and1004 is controlled by embedded circuitry, which specifies different modes of light-sensing. The modes include a reset mode, an integration mode, and a readout mode. During the reset mode, a charge storage component of a pixel is reset to a known voltage level. During the integration mode, the pixel is switched to an “on” state. Light that reaches a sensing area or element of the pixel causes a charge to accumulate in a charge storage component (e.g., a capacitor). The amount of stored electrical charge corresponds to the amount of light incident on the sensing element during the integration mode. During the readout mode, the amount of electrical charge is converted into a digital value and read out of theoptical image sensors746 and748 via the embedded circuitry and transmitted to theimage sensor controller1502. To read every pixel, the charge storage component of each pixel in a given region is connected sequentially by switched internal circuitry to a readout circuit, which performs the conversion of the electrical charge from an analog value to digital data. In some embodiments, the pixel analog data is converted to 12-bit digital data. However, it should be appreciated that the resolution may be less or greater based on allowances for noise, settling time, frame rate, and data transmission speed. The digital pixel data of each pixel may be stored to a register.
• Theexample processor1504 of theimage sensor controller1502 ofFIG. 15 is configured to receive pixel data (e.g., digital data indicative of an electrical charge stored in the pixel corresponding to an amount of incident light on an element of the pixel) from each of the pixels within the pixel sets1006 and1008. Theprocessor1504 forms a right image from the pixel data received from the rightoptical image sensor746. In addition, theprocessor1504 forms a left image from the pixel data received from the leftoptical image sensor748. Alternatively, theprocessor1504 forms only a portion (for example, one row or several rows) of each the left and right images before transmitting the data downstream. In some embodiments, theprocessor1504 uses a register location to determine a location of each pixel within an image.
• After the right and left images are created, theprocessor1504 synchronizes the right and left images. Theprocessor1504 then transmits both of the right and left images to thecommunications interface1508, which processes the images into a format for transmission to theinformation processor module1408 via acommunications channel1514. In some embodiments, thecommunications channel1514 conforms to the USB 2.0 or 3.0 standard and may comprise a copper or fiber optical cable. Thecommunications channel1514 may enable up to approximately 60 pairs (or more) of left and right images (having a stereoscopic resolution of 1920×1080 and a data conversion resolution of 12-bits) per second to be transmitted per second. The use of a copper USB cable enables power to be provided from theinformation processor module1408 to theimage capture module1404.
• The sections below further describe features provided by theprocessor1504 of theimage sensor controller1502 executingcertain programs1510 to acquire and/or process image data from theoptical image sensors746 and748.
1. Exposure Example
• Theexample processor1504 may control or program an amount of time theoptical image sensors746 and748 are in the integration mode, discussed above. The integration mode occurs for a time period referred to as an exposure time. Theprocessor1504 may set the exposure time by writing a value to an exposure register of theoptical image sensors746 and748. Additionally or alternatively, theprocessor1504 may transmit instructions to theoptical image sensors746 and748 signaling the start and end of the exposure time. The exposure time may be programmable between a few milliseconds (“ms”) to a few seconds. Preferably the exposure time is approximately the inverse of the frame rate.
• In some embodiments, theprocessor1504 may apply a rolling shutter method to theoptical image sensors746 and748 to read pixel data. Under this method, the exposure time for a given row of pixels of the pixel sets1006 and1008 begins just after the pixels in that row have been read out and then reset. A short time later, the next row (which is typically physically most proximate to the row just set) is read, and accordingly reset with its exposure time restarted. The sequential reading of each pixel row continues until the last or bottom row of the pixel sets1006 and1008 have been read and reset. Theprocessor1504 then returns to the top row of the pixel sets1006 and1008 to read pixel data for the next image.
• In another embodiment, theprocessor1504 applies a global shutter method. Under this method, theprocessor1504 implements readout and reset in a manner similar to the rolling shutter method. However, in this method integration occurs simultaneously for all pixels in the pixel sets1006 and1008. The global shutter method has the advantage of reducing defects in an image compared to the rolling shutter method since all of the pixels are exposed at the same time. In comparison, in the rolling shutter method, there is a small time delay between exposing the lines of the pixel set. Small defects can develop during the times between line exposures, especially between top lines and bottom lines where small changes at thetarget site700 between reads can occur.
2. Dynamic Range Example
• Theexample processor1504 may execute one ormore programs1510 to detect light that is outside of a dynamic range of theoptical image sensors746 and748. Generally, extremely bright light completely fills a charge storage region of a pixel, thereby resulting in lost image information regarding the exact brightness level. Similarly, extremely low light or lack of light fails to impart a meaningful charge in a pixel, which also results in lost image information. Images created from this pixel data accordingly do not accurately reflect the light intensity attarget site700.
• To detect light that is outside the dynamic range, theprocessor1504 may execute one of several high dynamic range (“HDR”)programs1510 including, for example, a multiple-exposure program, a multi-slope pixel integration program, and a multi-sensor image fusion program. In an example, the multiple-exposure program may utilize HDR features integrated or embedded with theoptical image sensors746 and748. Under this method, the pixel sets1006 and1008 are placed into the integration mode for a normal expose time. The lines of the pixel sets1006 and1008 are read and stored in a memory at theoptical image sensors746 and748 and/or thememory1506 of theimage sensor controller1502. After the read is performed by theprocessor1504, each line in the pixel sets1006 and1008 is turned on again for a second exposure time that is less than the normal exposure time. Theprocessor1504 reads each of the lines of pixels after the second exposure time and combines this pixel data with the pixel data from the normal exposure time for the same lines. Theprocessor1504 may apply tone-mapping to choose between (or combine) the pixel data from the normal-length and short-length exposure times and map the resulting pixel data to a range that is compatible with downstream processing and display. Using the multiple-exposure program, theprocessor1504 is able to expand the dynamic range of theoptical image sensors746 and748 and compress the resulting range of pixel data for display.
• Theprocessor1510 may operate a similar program for relatively dark light. However, instead of the second exposure time being less than the normal time, the second exposure time is greater than the normal time, thereby providing the pixels more time to accumulate a charge. Theprocessor1510 may use tone-mapping to adjust the read pixel data to compensate for the longer exposure time.
3. Frame Rate Example
• Theexample processor1510 may control or specify a frame rate for theoptical image sensors746 and748. In some embodiments, theoptical image sensors746 and748 include on-board timing circuitry and programmable control registers to specify the number of times per second each of the pixels within the pixel sets1006 and1008 are to be cycled through the imaging modes discussed above. A frame or image is formed each time the pixel set progresses through the three modes. A frame rate is the number of times per second the pixels in the pixel sets1006 and1008 are integrated, read, and reset.
• Theprocessor1510 may be synchronized with theoptical image sensors746 and748 such that reads are conducted at the appropriate time. In other examples, theprocessor1510 is asynchronous with theoptical image sensors746 and748. In these other examples, theoptical image sensors746 and748 may store pixel data after a local read to a temporary memory or queue. The pixel data may then be read periodically by theprocessor1510 for right and left image synchronization.
• The processing of frames or images in a time-sequential manner (e.g., creation of an image stream) provides an illusion of motion conveyed as a video. Theexample processor1510 is configured to program a frame rate that provides the appearance of a smooth video to an observer. A frame rate that is too low makes any motion appear choppy or uneven. Movie quality above a maximum threshold frame rate is not discernible to an observer. Theexample processor1510 is configured to generate approximately 20 to 70 frames per second, preferably between 50 and 60 frames per second for typical surgical visualization.
4. Sensor Synchronization Example
• Theexample processor1504 ofFIG. 15 is configured to control the synchronization of theoptical image sensors746 and748. Theprocessor1504 may, for instance, provide power simultaneously to theoptical image sensors746 and748. Theprocessor1504 may then provide a clock signal to both of theoptical image sensors746 and748. The clock signal enables theoptical image sensors746 and748 to operate independently in a free-run mode but in a synchronized and/or simultaneous manner. Accordingly, theoptical image sensors746 and748 record pixel data at nearly the same time. Theexample processor1504 receives the pixel data from theoptical image sensors746 and748, constructs at least a fraction of the images and/or frames and synchronizes the images and/or frames (or fraction thereof) to account for any slight timing mismatches. Typically, the lag between theoptical image sensors746 and748 is less than 200 microseconds. In other embodiments, theprocessor1504 may use a synchronization pin to simultaneously activate theoptical image sensors746 and748 after, for example, each reset mode.
B. Example Motor and Lighting Module
• The examplestereoscopic visualization camera300 ofFIG. 15 includes the motor andlighting module1406 to control one or more motors or actuators for moving lenses of theoptical elements1402 and/or controlling lighting output from the light sources708. The example motor andlighting module1406 includes a motor andlighting controller1520 that contains aprocessor1522, amemory1524, and acommunications interface1526 that are communicatively coupled together viacommunication bus1528. Thememory1524 stores one ormore programs1530 that are executable on theprocessor1522 to perform control, adjustment, and/or calibration of the lenses of theoptical elements1402 and/or the light sources708. In some embodiments, theprograms1530 may be transmitted to thememory1524 from theinformation processor module1408 and/or theuser input device1410.
• Thecommunications interface1526 is communicatively coupled to thecommunications interface1508 of theimage capture module1404 and acommunications interface1532 of theinformation processor module1408. Thecommunications interface1526 is configured to receive command messages, timing signals, status messages, etc. from theimage capture module1404 and theinformation processor module1408. For example, theprocessor1504 of theimage capture module1404 may send timing signals to theprocessor1522 to synchronize timing between lighting control and exposure time of theoptical image sensors746 and748. In another example, theinformation processing module1408 may send command messages instructing certain light sources708 to be activated and/or certain lenses of theoptical elements1402 to be moved. The commands may be in response to input received from an operator via, for example, theuser input device1410. Additionally or alternatively, the commands may be in response to a calibration routine and/or real-time adjustment to reduce or eliminate image misalignment and/or defects such as spurious parallax.
• The example motor andlighting module1406 includes drivers that provide power to control motors for adjusting an axial and/or radial position of the lenses of theoptical elements1402 and/or the light output from the light sources708. Specifically, the motor andlighting module1406 includes aNUV light driver1534 to transmit a NUV signal to the NUVlight source708c, aNIR light driver1536 to transmit a NIR signal to the NIRlight source708b, and avisible light driver1538 to transmit a visible light signal to the visiblelight source708a.
• In addition, the motor andlighting module1406 includes afilter motor driver1540 to transmit a filter motor signal to afilter motor1542, which controls thefilter740 ofFIGS. 7 and 8. The motor andlighting module1406 includes a rear zoomlens motor driver1544 to transmit a rear zoom lens motor signal to a rearzoom lens motor1546, a front zoomlens motor driver1548 to transmit a front zoom lens motor signal to a frontzoom lens motor1550, and a rear working distancelens motor driver1552 to transmit a working distance lens motor signal to a workingdistance lens motor1554. The motor andlighting module1406 may also include a motor and/or actuator to move and/or tilt the deflectingelement712.
• The rearzoom lens motor1546 is configured to rotate a drive screw that causescarrier730 to move axially along a track or rail. The frontzoom lens motor1550 is configured to rotate a drive screw that causescarrier724 to move axially along thetrack1106 shown inFIGS. 11 and 12. The workingdistance lens motor1554 is configured to rotate a drive screw that causes the rearworking distance lens702 to move axially along a track or rail.
• Thedrivers1536,1538, and1540 may include any type of lighting driver, transformer, and/or ballast. Thedrivers1536,1538, and1540 are configured to output a pulse width modulation (“PWM”) signal to control an intensity of light output by the light sources708. In some embodiments, theprocessor1522 may control the timing of thedrivers1536,1538, and1540 to correspond to a timing for applying a certain filter using thefilter motor driver1540.
• Theexample drivers1540,1544,1548, and1552 may include, for example stepper motor drivers and/or DC motor drivers. Likewise, themotors1542,1546,1550, and/or1554 may include a stepper motor, a DC motor, or other electrical, magnetic, thermal, hydraulic, or pneumatic actuator. Themotors1542,1546,1550, and/or1554 may include, for example, a rotary encoder, a slotted optical switch (e.g., a photointerrupter), and/or a linear encoder to report an angular position of a shaft and/or axle for feedback reporting and control. Alternative embodiments may include voice-coil motors, piezoelectric motors, linear motors, with suitable drivers, and equivalents thereof.
• To control thedrivers1534,1536,1538,1540,1544,1548, and1552, theprocessor1522 is configured to use aprogram1530 for converting a command message into a digital and/or analog signal. Theprocessor1522 transmits the digital and/or analog signal to the appropriate driver, which outputs an analog power signal, such as a PWM signal corresponding to the received signal. The analog power signal provides power to an appropriate motor or actuator causing it to rotate (or otherwise move) by a desired amount.
• Theprocessor1522 may receive feedback from thedrivers1534,1536,1538,1540,1544,1548, and1552, themotors1542,1546,1550, and/or1554, and/or the light sources708. The feedback corresponds to, for example, a lighting level or lighting output. Regarding the motors, the feedback corresponds to a position of a motor (or other actuator) and/or an amount of movement. Theprocessor1522 uses aprogram1530 to translate the received signal into digital feedback to determine, for example, a radial, tilt, and/or axial position of a lens based on an angular position of the corresponding motor or actuator shaft. Theprocessor1522 may then transmit a message with the position information to theinformation processor module1408 for display to a user and/or to track a position of the lenses of theoptical elements1402 for calibration.
• In some embodiments, the motor andlighting module1406 may include additional drivers to change an axial, tilt, and/or radial position of individual lenses within theoptical elements1402. For example, the motor andlighting module1406 may include drivers that control motors for actuatingflexures750 and752 for theoptical image sensors746 and748 for tilting and/or radial/axial adjustment. Further, the motor andlighting module1406 may include drivers that control motors (or actuators) for individually tilting and/or adjustingfront lenses720 and722, thefront zoom lenses726 and728, therear zoom lenses732 and734, the lens barrels736 and738, and/or finaloptical elements745 and747 radially along an x-axis or y-axis and/or axially. Independent adjustment of the lenses and/or sensors enables, for example, the motor andlighting controller1520 to remove image defects and/or align the left and right images.
• The following sections describe how theprocessor1552 executes one ormore programs1530 to change a working distance, zoom, filter position, lens position, and/or light output.
1. Working Distance Example
• Theexample processor1522 of the motor andlighting module1406 ofFIG. 15 is configured to adjust a working distance of thestereoscopic visualization camera300. The working distance is set by adjusting a distance between the rearworking distance lens704 and the frontworking distance lens408. Theprocessor1522 adjusts the distance by causing the rearworking distance lens704 to move relative to the frontworking distance lens408. Specifically, theprocessor1522 sends a signal to the rear working distancelens motor driver1552, which activates the workingdistance lens motor1554 for a predetermined time proportional to an amount the rearworking distance lens704 is to be moved. The workingdistance lens motor1554 drives a leadscrew through threads attached to a sliding track that holds the rearworking distance lens704. The workingdistance lens motor1554 causes thelens704 to move a desired distance, thereby adjusting the working distance. The workingdistance lens motor1554 may provide a feedback signal to theprocessor1522, which determines if the rearworking distance lens704 was moved the desired amount. If the movement is less or more than desired, theprocessor1522 may send instructions further refining the position of the rearworking distance lens704. In some embodiments, theinformation processor module1408 may determine feedback control for the rearworking distance lens704.
• To determine a position of the rearworking distance lens704, theprocessor1522 may operate one ormore calibration programs1530. For example, upon activation, theprocessor1522 may instruct the workingdistance lens motor1554 to drive a leadscrew to move the rearworking distance lens704 along a track or rail until triggering a limit switch at one end of the motion range. Theprocessor1522 may designate this stop position as a zero-point for the encoder of themotor1554. Having knowledge of the current position of the rearworking distance lens704 and the corresponding encoder value, theprocessor1522 becomes capable of determining a number of shaft rotations to cause the rearworking distance lens704 to move to a desired position. The number of shaft rotations is transmitted in an analog signal to the working distance lens motor1554 (via the driver1552) to accordingly move thelens704 to a specified position.
2. Zoom Example
• Theexample processor1522 ofFIG. 15 is configured to execute one ormore programs1530 to change a zoom level of thestereoscopic visualization camera300. As discussed above, zoom (e.g., magnification change) is achieved by changing positions of the front zoom set724 and the rear zoom set730 relative to each other and relative to the front lens set714 and the lens barrel set718. Similar to the calibration procedure described above for the rearworking distance lens704, theprocessor1522 may calibrate positions of thesets724 and730 along tracks or rails. Specially, theprocessor1522 sends instructions causing the rearzoom lens motor1546 and the frontzoom lens motor1550 to move thesets724 and730 (e.g., carriers) along a rail (or rails) to a stop position at a limit switch. Theprocessor1522 receives encoder feedback from themotors1546 and1550 to determine an encoder value associated with the stop position for thesets724 and730. Theprocessor1522 may then zero-out the encoder value or use the known encoder value at the stop position to determine how much themotors1546 and1550 are to be activated to achieve a desired position for thesets724 and730 along the rail.
• In addition to calibration for stop position, theprocessor1522 may executeprograms1530 that define locations forsets724 and730 to achieve a desired zoom level. For example, a known pattern of distance settings versus a set of desired zoom values may be stored as a program1530 (or a look-up table) during a calibration procedure. The calibration procedure may include placing a template within thetarget site700 and instructing the processor522 to move thesets724 and730 until a certain designated marker or character is a certain size in right and left images or frames. For example, a calibration routine may determine positions of theset724 and730 on a rail corresponding to when character “E” on a template at thetarget site700 is displayed in right and left images as having a height of 10 pixels.
• In some embodiments, theinformation processor module1408 may perform the visual analysis and send instructions to theprocessor1522 regarding desired movement for thesets724 and730 to zoom in or zoom out. In addition, theinformation processor1408 may send instructions for moving the focal plane such that thetarget site700 at the desired zoom level is in focus. The instructions may include, for example, instructions to move the rearworking distance lens704 and/or moving thesets724 and730 together and/or individually. In some alternative embodiments, theprocessor1522 may receive calibration parameters for the rail position of the front zoom set724 and the rear zoom set730 at certain zoom levels from theuser input device1410 or another computer.
• Theexample processor1522 and/or theinformation processor module1408 may send instructions such that an image remains in focus while magnification changes. Theprocessor1522, for example, may use aprogram1530 and/or a look-up-table to determine how certain lenses are to be moved along an optical axis to retain focus on thetarget site700. Theprograms1530 and/or look-up-table may specify magnification levels and/or set points on a rail and corresponding lens adjustments needed to keep the focal plane from moving.
• Table 2 below shows anexample program1530 or look-up-table that may be used by theprocessor1522 to retain focus while changing magnification. The position of the front zoom lens set724 and the rear zoom lens set730 is normalized based on a length of a rail to stop positions for therespective sets724 and730. To decrease magnification, the rear zoom lens set is moved toward the lens barrel set718, thereby increasing a position along a rail. The front zoom lens set724 is also moved. However, its movement does not necessarily equal the movement of the rear zoom lens set730. Instead, the movement of the front zoom lens set724 accounts for changing a distance between thesets724 and730 to retain the position of the focal plane to maintain focus while changing magnifications. For example, to decrease a magnification level from 10× to 9×, theprocessor1522 instructs the rear zoom lens set730 to move fromposition 10 to position 11 along a rail. In addition, theprocessor1522 instructs the front zoom lens set724 to move fromposition 5 toposition 4 along a rail (or same rail as the set730). Not only have thesets724 and730 moved to change magnification, thesets724 and730 have moved relative to each other to retain focus.

• TABLE 2
  	Front Zoom	Rear Zoom
  Magnification	Lens Set Position	LensSet Position

  10X

  	5	10
  9X	4	11
  8X	3	12
  7X	4.5	14
  6X	6	17
  5X	8	20

• It should be appreciated that Table 2 provides an example of how thesets724 and730 may be moved. In other examples, Table 2 may include additional rows to account for more precise magnifications and/or positions of thesets724 and730. Additionally or alternatively, Table 2 may include a column for the rearworking distance lens704. For example, the rearworking distance lens704 may be moved instead of or in conjunction with the front zoom lens set724 to retain focus. Further, Table 2 may include rows specifying positions for thesets724 and730 and the rearworking distance lens704 to retain focus during changes in working distance.
• The values in Table 2 may be determined through calibration and/or received from a remote computer or theuser input device1410. During calibration, theinformation processor module1408 may operate acalibration program1560 that progresses through different magnifications and/or working distances. Aprocessor1562 at theinformation processor module1408 may perform image processing of the images themselves or received pixel data to determine when a desired magnification is achieved using, for example, a template with predetermined shapes and/or characters. Theprocessor1562 determines if the received images are in-focus. Responsive to determining images are out of focus, theprocessor1562 sends instructions to theprocessor1522 to adjust the front zoom lens set724 and/or the rear workingdistance lens set704. The adjustment may include iterative movements in forward and reverse directions along an optical path until theprocessor1562 determines images are in focus. To determine an image is in focus, theprocessor1562 may perform, for example, image analysis searching for images where light fuzziness is minimal and/or analyzing pixel data for differences in light values between adjacent pixel regions (where greater differences correspond to more in focus images). After determining an image is in focus at a desired working distance and magnification, theprocessor1562 and/or theprocessor1522 may then record positions of thesets724 and730 and/or the rearworking distance lens704 and corresponding magnification level.
3. Filter Position Example
• Theexample processor1522 of the motor andlighting module1406 ofFIG. 15 is configured to move thefilter740 into the right and left optical paths based on received instructions. In some examples, thefilter740 may include a mirror array. In these examples, theprocessor1522 sends instructions to thefilter motor driver1540 to actuate one ormore motors1542 to change positions of the mirrors. In some instances, thedriver1540 may send an electrical charge along one or more paths to thefilter740, causing certain mirror elements to switch to an on or off position. In these examples, the filter type selection is generally binary based on which mirrors to actuate.
• In other examples, thefilter740 may include a wheel with different types of filters such as an infrared cut filter, near-infrared bandpass filter, and near-ultraviolet cut filter. In these examples, the wheel is rotated by thefilter motor1542. Theprocessor1522 determines stop positions of the wheel corresponding to partitions between the different filters. Theprocessor1522 also determines rotary encoder value corresponding to each of the stop positions.
• Theprocessor1522 may operate acalibration program1530 and/or theprocessor1562 may operate acalibration program1560 to determine the stop positions. For example, theprocessor1522 may rotate thefilter wheel740 slowly, with theprocessor1562 determining when light received at the pixels changes (using either image analysis or reading pixel data from the image capture module1404). A change in a light value at the pixels is indicative of a change in the filter type being applied to the optical paths). In some instances, theprocessor1522 may change which light sources708 are activated to create further distinction at the pixels when a different filter type is applied.
4. Light Control and Filter Example
• As disclosed above, theprocessor1522 may control the light sources708 in conjunction with thefilter740 to cause light of a desired wavelength to reach theoptical image sensors746 and748. In some examples, theprocessor1522 may control or synchronize timing between activation of one or more of the light sources708 and one or more of thefilters740. To synchronize timing, aprogram1530 may specify a delay time for activating a certain filter. Theprocessor1522 uses thisprogram1530 to determine when, for example a signal to activate thefilter740 is to be transmitted relative to sending a signal to turn on a light source708. The scheduled timing ensures theappropriate filter740 is applied when the specified light source708 is activated. Such a configuration enables features highlighted by one light source708 (such as fluorescence) to be shown on top of or in conjunction with features displayed under a second light source708, such as white or ambient light.
• In some instances, the light sources708 may be switched as fast as the light filters740 may be changed, thereby enabling images recorded in different lights to be shown in conjunction on top of each other. For example, veins or other anatomical structures that emit fluorescence (due to an administered dye or contrast agent) may be shown on top of an image under ambient lighting. In this example, the veins would be highlighted relative to the background anatomical features shown in visible light. In this instance, theprocessor1562 and/or a graphics processing unit1564 (e.g., a video card or graphics card) of theinformation processor module1408 combines or overlays one or more images recorded during application of one filter with images recorded during application of a subsequent filter.
• In some embodiments, theprocessor1522 may activate multiple light sources708 at the same time. The light sources708 can be activated simultaneously or sequentially to “interleave” light of different wavelengths to enable different information to be extracted using appropriate pixels at theoptical image sensors746 and748. Activating the light sources simultaneously may help illuminate dark fields. For example, some applications use UV light to stimulate fluorescence at atarget site700. However, UV light is perceived by an operator as being very dark. Accordingly, theprocessor1522 may activate thevisible light source1538 periodically to add some visible light to the viewing field so that the surgeon can observe the field-of-view without overwhelming pixels that are sensitive to UV light but can also detect some visible light. In another example, alternating between light sources708 avoids, in some instances, washing out pixels of theoptical image sensors746 and748 that have overlapping sensitivity at the edges of their ranges.
5. Light Intensity Control
• Theexample processor1522 ofFIG. 15 is configured to execute one ormore programs1530 to change an intensity of or a level of illumination provided by the light sources708. It should be appreciated that the depth of field is dependent on the level of illumination at thetarget site700. Generally, higher illumination provides a greater depth of field. Theprocessor1522 is configured to ensure an appropriate amount of illumination is provided for a desired depth of field without washing out or overheating the field-of-view.
• The visiblelight source708ais driven by thevisible light driver1538 and outputs light in the human-visible part of the spectrum as well as some light outside that region. The NIRlight source708bis driven by theNIR light driver1536 and outputs light primarily at a wavelength that referred to as near-infrared. The NUVlight source708cis driven by theNUV light driver1534 and outputs light primarily at a wavelength that is deep in the blue part of the visible spectrum, which is referred to as near-ultraviolet. The respectivelight drivers1534,1536, and1538 are controlled by commands provided by theprocessor1522. Control of the respective output spectra of the light sources708 is achieved by PWM signal, where a control voltage or current is switched between a minimum (e.g., off) and maximum (e.g., on) value. The brightness of the light that is output from the light sources708 is controlled by varying the switching rate as well as the percentage of time the voltage or current is at the maximum level per cycle in the PWM signal.
• In some examples, theprocessor1522 controls an output of the light sources708 based on a size of the field-of-view or zoom level. Theprocessor1522 may execute aprogram1530 that specifies for certain light sensitive settings that light intensity becomes a function of zoom. Theprogram1530 may include, for example a look-up-table that correlates a zoom level to a light intensity value. Theprocessor1522 uses theprogram1530 to select the PWM signal for the light source708 based on the selected magnification level. In some examples, theprocessor1522 may reduce light intensity as the magnification increases to maintain the amount of light provided to the field-of-view per unit of area.
C. Example Information Processor Module
• The exampleinformation processor module1408 within thestereoscopic visualization camera300 ofFIG. 15 is configured to analyze and process images/frames received from theimage capture module1404 for display. In addition, theinformation processor module1408 is configured to interface with different devices and translate control instructions into messages for theimage capture module1404 and/or the motor andlighting module1406. Theinformation processor module1408 may also provide an interface for manual calibration and/or manage automatic calibration of theoptical elements1402.
• As shown inFIG. 15, theinformation processor module1408 is communicatively and/or electrically coupled to theimage capture module1404 and the motor andlighting module1406. For example, thecommunications channel1514 in addition tocommunications channels1566 and1568 may include USB 2.0 or USB 3.0 connections. As such, theinformation processor module1408 regulates and provides power to themodules1404 and1406. In some embodiments, theinformation processor module1408 converts 110-volt alternating current (“AC”) power from a wall outlet into a 5, 10, 12, and/or 24 volt direct current (“DC”) supply for themodules1404 and1406. Additionally or alternatively, theinformation processor module1408 receives electrical power from a battery internal to thehousing302 of thestereoscopic visualization camera300 and/or a battery at thecart510.
• The exampleinformation processor module1408 includes thecommunications interface1532 to communicate bidirectionally with theimage capture module1404 and the motor andlighting module1406. Theinformation processor module1408 also includes theprocessor1562 configured to execute one ormore programs1560 to process images/frames received from theimage capture module1404. Theprograms1560 may be stored in amemory1570. In addition theprocessor1562 may perform calibration of theoptical elements1402 and/or adjust theoptical elements1402 to align right and left images and/or remove visual defects.
• To process images and/or frames into a rendered three-dimensional stereoscopic display, the exampleinformation processor module1408 includes thegraphics processing unit1564.FIG. 16 shows a diagram of thegraphics processing unit1564, according to an example embodiment of the present disclosure. During operation, theprocessor1562 receives images and/or frames from theimage capture module1404. An unpack routine1602 converts or otherwise changes the images/frames from a format conducive for transmission across thecommunications channel1514 into a format conducive for image processing. For instance, the images and/or frames may be transmitted across thecommunications channel1514 in multiple messages. The example unpack routine1602 combines the data from the multiple messages to reassemble the frames/images. In some embodiments, theunpack routine1602 may queue frames and/or images until requested by thegraphics processing unit1564. In other examples, theprocessor1562 may transmit each right and left image/frame pair after being completely received and unpacked.
• The examplegraphics processing unit1564 uses one or more programs1580 (shown inFIG. 15) to prepare images for rendering. Examples of theprograms1580 are shown inFIGS. 15 and 16. Theprograms1580 may be executed by a processor of thegraphics processing unit1564. Alternatively, each of theprograms1580 shown inFIG. 16 may be executed by a separate graphics processor, microcontroller, and/or application specific integrated circuit (“ASIC”). For example, ade-Bayer program1580ais configured to smooth or average pixel values across neighboring pixels to compensate for a Bayer pattern applied to thepixel grids1002 and1004 of the right and leftoptical image sensors746 and748 ofFIGS. 7 and 8. Thegraphics processing unit1564 may also includeprograms1580b,1580c, and1580dfor color correction and/or white balance adjustment. Thegraphics processing unit1564 also includes arenderer program1580efor preparing color corrected images/frames for display on the display monitors512 and514. Thegraphics processing unit1564 may further interact and/or include a peripheralinput unit interface1574, which is configured to combine, fuse, or otherwise include other images and/or graphics for presentation with the stereoscopic display of thetarget site700. Further details of theprograms1580 and theinformation processor module1408 more generally are discussed below.
• The exampleinformation processor module1408 may execute one ormore programs1562 to check for and improve latency of thestereoscopic visualization camera300. Latency refers to the amount of time taken for an event to occur at thetarget site700 and for that same event to be shown by the display monitors512 and514. Low latency provides a feeling that thestereoscopic visualization camera300 is an extension of a surgeon's eyes while high latency tends to distract from the microsurgical procedure. Theexample processor1562 may track how much time elapses between images being read from theoptical image sensors746 and748 until the combined stereoscopic image based on the read images is transmitted for display. Detections of high latency may cause theprocessor1562 to reduce queue times, increase the frame rate, and/or skip some color correction steps.
1. User Input Example
• Theexample processor1562 of theinformation processor module1408 ofFIG. 15 is configured to convert user input instructions into messages for the motor andlighting module1406 and/or theimage capture module1402. User input instructions may include requests to change optical aspects of thestereoscopic visualization camera300 including a magnification level, a working distance, a height of a focal plane (e.g., focus), a lighting source708, and/or a filter type of thefilter740. The user input instructions may also include requests to perform calibration, including indications of an image being in focus and/or indications of image alignment, and/or indications of aligned ZRPs between left and right images. The user input instructions may further include adjustments to parameters of thestereoscopic visualization camera300, such as frame rate, exposure time, color correction, image resolution, etc.
• The user input instructions may be received from auser input device1410, which may include the controls305 of the control arm304 ofFIG. 3 and/or a remote control. Theuser input device1410 may also include a computer, tablet computer, etc. In some embodiments, the instructions are received via anetwork interface1572 and/or a peripheralinput unit interface1574. In other embodiments, the instructions may be received from a wired connection and/or a RF interface.
• Theexample processor1562 includesprograms1560 for determining an instruction type and determining how the user input is to be processed. In an example, a user may press a button of the control305 to change a magnification level. The button may continue to be pressed until the operator has caused thestereoscopic visualization camera300 to reach a desired magnification level. In these examples, the user input instructions include information indicative that a magnification level is to be, for example, increased. For each instruction received (or each time period in which a signal indicative of the instruction is received), theprocessor1562 sends a control instruction to the motor andlighting processor1406 indicative of the change in magnification. Theprocessor1522 determines from aprogram1530 how much the zoom lens sets724 and730 are to be moved using, for example, Table 2. Theprocessor1522 accordingly transmits a signal or message to the rear zoomlens motor driver1544 and/or the front zoomlens motor driver1548 causing the rearzoom lens motor1546 and/or the frontzoom lens motor1550 to move the rear zoom lens set730 and/or the front zoom lens set724 by an amount specified by theprocessor1562 to achieve the desired magnification level.
• It should be appreciated that in the above example, thestereoscopic visualization camera300 provides a change based on user input but also makes automatic adjustments to maintain focus and/or a high image quality. For instance, instead of simply changing the magnification level, theprocessor1522 determines how the zoom lens sets724 and730 are to be moved to also retain focus, thereby saving an operator from having to perform this task manually. In addition, theprocessor1562 may, in real-time, adjust and/or align ZRPs within the right and left images as a magnification level changes. This may be done, for example, by selecting or changing locations of the pixel sets1006 and1008 with respect topixel grids1002 and1004 ofFIG. 10.
• In another example, theprocessor1562 may receive an instruction from theuser input device1410 to change a frame rate. Theprocessor1562 transmits a message to theprocessor1504 of theimage capture module1404. In turn, theprocessor1504 writes to registers of the right and leftimage sensors746 and748 indicative of the new frame rate. Theprocessor1504 may also update internal registers with the new frame rate to change a pace at which the pixels are read.
• In yet another example, theprocessor1562 may receive an instruction from theuser input device1410 to begin a calibration routine for ZRP. In response, theprocessor1562 may execute aprogram1560 that specifies how the calibration is to be operated. Theprogram1560 may include, for example, a progression or iteration of magnification levels and/or working distances in addition to a routine for verifying image quality. The routine may specify that for each magnification level, focus is to be verified in addition to ZRP. The routine may also specify how the zoom lens sets724 and730 and/or the rearworking distance lens704 are to be adjusted to achieve an in focus image. The routine may further specify how ZRP of the right and left images are to be centered for the magnification level. Theprogram1560 may store (to a look-up-table) locations of zoom lens sets724 and/or the730 and/or the rearworking distance lens704 in addition to locations of pixel sets1006 and1008 and the corresponding magnification level once image quality has been verified. Thus, when the same magnification level is requested at a subsequent time, theprocessor1562 uses the look-up-table to specify positions for the zoom lens sets724 and/or the730 and/or the rearworking distance lens704 to the motor andlighting module1406 and positions for the pixel sets1006 and1008 to theimage capture module1404. It should be appreciated that in some calibration routines, at least some of the lenses of theoptical elements1402 may be adjusted radially/rotationally and/or tilted to center ZRPs and/or align right and left images.
2. Interface Example
• To facilitate communications between thestereoscopic visualization camera300 and external devices, the exampleinformation processor module1408 includes thenetwork interface1572 and the peripheralinput unit interface1574. Theexample network interface1572 is configured to enable remote devices to communicatively couple to theinformation processor module1408 to, for example, store recorded video, control a working distance, zoom level, focus, calibration, or other features of thestereoscopic visualization camera300. In some embodiments, the remote devices may provide values or parameters for calibration look-up-tables or more generally,programs1530 with calibrated parameters. Thenetwork interface1572 may include an Ethernet interface, a local area network interface, and/or a Wi-Fi interface.
• The example peripheralinput unit interface1574 is configured to communicatively couple to one or moreperipheral devices1576 and facilitate the integration of stereoscopic image data with peripheral data, such as patient physiological data. The peripheralinput unit interface1574 may include a Bluetooth® interface, a USB interface, an HDMI interface, SDI, etc. In some embodiments, the peripheralinput unit interface1574 may be combined with thenetwork interface1572.
• Theperipheral devices1576 may include, for example, data or video storage units, patient physiological sensors, medical imaging devices, infusion pumps, dialysis machines, and/or tablet computers, etc. The peripheral data may include image data from a dedicated two-dimensional infrared-specialized camera, diagnostic images from a user's laptop computer, and/or images or patient diagnostic text from an ophthalmic device such as the Alcon Constellation® system and the WaveTec Optiwave Refractive Analysis (ORA™) system.
• The example peripheralinput unit interface1574 is configured to convert and/or format data from theperipheral devices1576 into an appropriate digital form for use with stereoscopic images. Once in digital form, thegraphics processing unit1564 integrates the peripheral data with other system data and/or the stereoscopic images/frames. The data is rendered with the stereoscopic images for display on the display monitors512 and/or514.
• To configure the inclusion of peripheral data with the stereoscopic images, theprocessor1562 may control an integration setup. In an example, theprocessor1562 may cause thegraphics processing unit1564 to display a configuration panel on the display monitors512 and/or514. The configuration panel may enable an operator to connect aperipheral device1576 to theinterface1574 and theprocessor1562 to subsequently establish communications with thedevice1576. Theprocessor1564 may then read which data is available or enable the operator to use the configuration panel to select a data directory location. Peripheral data in the directory location is displayed in the configuration panel. The configuration panel may also provide the operator an option to overlay the peripheral data with stereoscopic image data or display as a separate picture.
• Selection of peripheral data (and overlay format) causes theprocessor1562 to read and transmit the data to thegraphics processing unit1564. Thegraphics processing unit1564 applies the peripheral data to the stereoscopic image data for presentation as an overlay graphic (such as fusing a preoperative image or graphic with a real-time stereoscopic image), a “picture-in-picture,” and/or a sub-window to the side or on top of the main stereoscopic image window.
3. De-Bayer Program Example
• Theexample de-Bayer program1580aofFIG. 16 is configured to produce images and/or frames with values for red, green, and blue color at every pixel value. As discussed above, the pixels of the right and leftoptical image sensors746 and748 have a filter that passes light in the red wavelength range, the blue wavelength range, or the green wavelength range. Thus, each pixel only contains a portion of the light data. Accordingly, each image and/or frame received in theinformation processor module1408 from theimage capture module1404 has pixels that contain either red, blue, or green pixel data.
• Theexample de-Bayer program1580ais configured to average the red, blue, and green pixel data of adjacent and/or neighboring pixels to determine more complete color data for each pixel. In an example, a pixel with red data and a pixel with blue data are located between two pixels with green data. The green pixel data for the two pixels is averaged and assigned to the pixel with red data and the pixel with blue data. In some instances, the averaged green data may be weighted based on a distance of the pixel with red data and the pixel with blue data from the respective green pixels. After the calculation, the pixels with originally only red or blue data now include green data. Thus, after thede-Bayer program1580ais executed by thegraphics processing unit1564, each pixel contains pixel data for an amount of red, blue, and green light. The pixel data for the different colors is blended to determine a resulting color on the color spectrum, which may be used by therenderer program1580efor display and/or the display monitors512 and514. In some examples, thede-Bayer program1580amay determine the resulting color and store data or an identifier indicative of the color.
4. Color Correction Example
• The examplecolor correction programs1580b,1580c, and1580dare configured to adjust pixel color data. The sensorcolor correction program1580bis configured to account or adjust for variability in color sensing of theoptical image sensors746 and748. The usercolor correction program1580cis configured to adjust pixel color data based on perceptions and feedback of an operator. Further, the displaycolor correction program1580dis configured to adjust pixel color data based on a display monitor type.
• To correct color for sensor variability, the examplecolor correction program1580bspecifies a calibration routine that is executable by thegraphics processing unit1564 and/or theprocessor1562. The sensor calibration includes placing a calibrated color chart, such as the ColorChecker® Digital SG by X-Rite, Inc. at thetarget site700. Theprocessor1562 and/or thegraphics processing unit1564 executes theprogram1580b, which includes sending instructions to theimage capture module1404 to record right and left images of the color chart. Pixel data from the right and left images (after being processed by thede-Bayer program1580a) may be compared to pixel data associated with the color chart, which may be stored to thememory1570 from aperipheral unit1576 and/or a remote computer via thenetwork interface1572. Theprocessor1562 and/or thegraphics processing unit1564 determines differences between the pixel data. The differences are stored to thememory1570 as calibration data or parameters. The sensorcolor correction program1580bapplies the calibration parameters to subsequent right and left images.
• In some examples, the differences may be averaged over regions of pixels such that theprogram1580bfinds a best-fit of color correction data that can be applied globally to all of the pixels of theoptical images sensors746 and748 to produce colors as close to the color chart as possible. Additionally or alternatively, theprogram1580bmay process user input instructions received from theuser unit device1410 to correct colors. The instructions may include regional and/or global changes to red, blue, and green pixel data based on operator preferences.
• The example sensorcolor correction program1580bis also configured to correct for white balance. Generally, white light should result in red, green, and blue pixels having equal values. However, differences between pixels can result from color temperature of light used during imaging, inherent aspects of the filter and sensing element of each of the pixels, and spectral filtering parameters of, for example, the deflectingelement712 ofFIGS. 7 and 8. The example sensorcolor correction program1580bis configured to specify a calibration routine to correct for the light imbalances.
• To perform white balance, the processor1562 (per instructions from theprogram1580b) may display an instruction on thedisplay monitor512 and/or514 for an operator to place a neutral card at thetarget site700. Theprocessor1562 may then instruct theimage capture module1404 to record one or more images of the neutral card. After processing by theunpack routine1602 and thede-Bayer program1580a, theprogram1580bdetermines regional and/or global white balance calibration weight values for each of the red, blue, and green data such that each of the pixels have substantially equal values of red, blue, and green data. The white balance calibration weight values are stored to thememory1570. During operation, thegraphics processing unit1564 uses theprogram1580bto apply the white balance calibration parameters to provide white balance.
• In some examples, theprogram1580bdetermines white balance calibration parameters individually for the right and leftoptical image sensors746 and748. Of these examples, theprogram1580bmay store separate calibration parameters for the left and right images. In other instances, the sensorcolor correction program1580bdetermines a weighting between the right and left views such that color pixel data is nearly identical for the right and leftoptical image sensors746 and748. The determined weight may be applied to the white balance calibration parameters for subsequent use during operation of thestereoscopic visualization camera300.
• In some embodiments, the sensorcolor correction program1580bofFIG. 16 specifies that the white balance calibration parameters are to be applied as a digital gain on the pixels of the right and leftoptical image sensors746 and748. For example, theprocessor1504 of theimage capture module1404 applies the digital gain to pixel data read from each of the pixels. In other embodiments, the white balance calibration parameters are to be applied as an analog gain for each pixel's color sensing element.
• The example sensorcolor correction program1580bmay perform white balancing and/or color correction when the different light sources708 and/or filter types of thefilter740 are activated. As a result, thememory1570 may store different calibration parameters based on which light source708 is selected. Further, the sensorcolor correction program1580bmay perform white balancing and/or color correction for different types of external light. An operator may use theuser input device1410 to specify characteristics and/or a type of the external light source. This calibration enables thestereoscopic visualization camera300 to provide color correction and/or white balance for different lighting environments.
• Theexample program1580bis configured to perform calibration on each of theoptical image sensors746 and748 separately. Accordingly, theprogram1580bapplies different calibration parameters to the right and left images during operation. However, in some examples, calibration may only be performed on onesensor746 or748 with the calibration parameters being used for the other sensor.
• The example usercolor correction program1580cis configured to request operator-provided feedback regarding image quality parameters such as brightness, contrast, gamma, hue, and/or saturation. The feedback may be received as instructions from theuser input device1410. Adjustments made by the user are stored as user calibration parameters in thememory1570. These parameters are subsequently applied by the usercolor correction program1580cto right and left optical images after color correction for theoptical image sensors746 and748.
• The example displaycolor correction program1580dofFIG. 16 is configured to correct image color for a display monitor using, for example, the Datacolor™ Spyder color checker. Theprogram1580d, similar to theprogram1580b, instructs theimage capture module1404 to record an image of a display color template at thetarget scene700. The displaycolor correction program1580doperates a routine to adjust pixel data to match an expected display output stored in a look-up-table in thememory1570. The adjusted pixel data may be stored as display calibration parameters to thememory1570. In some examples, a camera or other imaging sensor may be connected to the peripheralinput unit interface1574, which provides images or other feedback regarding color recorded from the display monitors512 and514, which is used to adjust the pixel data.
5. Stereoscopic Image Display Example
• Theexample renderer program1580eof thegraphics processing unit1564 ofFIG. 16 is configured to prepare right and left images and/or frames for three-dimensional stereoscopic display. After the pixel data of the right and left images is color corrected by theprograms1580b,1580c, and1580d, therenderer program1580eis configured to draw left-eye and right-eye data into a format suitable for stereoscopic display and place the final rendered version into an output buffer for transmission to one of the display monitors512 or514.
• Generally, therenderer program1580ereceives a right image and/or frame and a left image and/or frame. Therenderer program1580ecombines the right and left images and/or frames into a single frame. In some embodiments, theprogram1580eoperates a top-bottom mode and condenses the left image data in height by half. Theprogram1580ethen places the condensed left image data in a top half of the combined frame. Similarly, theprogram1580econdenses the right image data in height by half and places the condensed right image data in a bottom half of the combined frame.
• In other embodiments, therenderer program1580eoperates a side-by-side mode where each of the left and right images are condensed in width by half and combined in a single image such that the left image data is provided on a left half of the image while right image data is provided on a right half of the image. In yet an alternative embodiment, therenderer program1580eoperates a row-interleaved mode where every other line in the left and right frames is discarded. The left and right frames are combined together to form a complete stereoscopic image.
• Theexample renderer program1580eis configured to render combined left and right images separately for each connected display monitor. For instance, if both the display monitors512 and514 are connected, therenderer program1580erenders a first combined stereoscopic image for thedisplay monitor512 and a second combined stereoscopic image for thedisplay monitor514. Therenderer program1580eformats the first and second combined stereoscopic images such that they are compatible with the type and/or screen size of the display monitors and/or screen.
• In some embodiments, therenderer program1580eselects the image processing mode based on how the display monitor is to display stereoscopic data. Proper interpretation of stereoscopic image data by the brain of an operator requires that the left eye data of the stereoscopic image be conveyed to the operator's left eye and the right eye data of the stereoscopic image be conveyed to the operator's right eye. Generally, display monitors provide a first polarization for left eye data and a second opposing polarization for the right eye data. Thus, the combined stereoscopic image must match the polarization of the display monitor.
• FIG. 17 shows an example of thedisplay monitor512, according to an example embodiment of the present disclosure. The display monitor512 may be, for example, the LG® 55LW5600 three-dimensional television with ascreen1702. The example display monitor512 uses a polarization film on thescreen1702 such that all odd rows1704 have a first polarization and all even rows1706 have an opposing polarization. For compatibility with the display monitor512 shown inFIG. 17, therenderer program1580ewould have to select the row-interleaved mode such that the left and right image data are on alternating lines. In some instances, therenderer program1580emay request (or otherwise receive) display characteristics of the display monitor512 prior to preparing the stereoscopic image.
• To view the stereoscopic image displayed on thescreen1702, the surgeon504 (remember him fromFIG. 5) wearsglasses1712 that include aleft lens1714 that comprises a first polarization that matches the first polarization of the rows1704. In addition, theglasses1712 include aright lens1716 that comprises a second polarization that matches the second polarization of the rows1706. Thus, theleft lens1714 only permits a majority of the light from the left image data from the left rows1704 to pass through while blocking a majority of the light from the right image data. In addition, theright lens1716 permits a majority of the light from the right image data from the right rows1706 to pass through while blocking a majority of the light from the left image data. The amount of light from the “wrong” view that reaches each respective eye is known as “crosstalk” and is generally held to a value low enough to permit comfortable viewing. Accordingly, thesurgeon504 views left image data recorded by the leftoptical image sensor748 in a left eye while viewing right image data recorded by the rightoptical image sensor746 in a right eye. The surgeon's brain fuses the two views together to create a perception of three-dimensional distance and/or depth. Further, the use of such a display monitor is advantageous for observing the accuracy of thestereoscopic visualization camera300. If the surgeon or operator does not wear glasses, then both left and right views are observable with both eyes. If a planar target is placed at the focal plane, the two images will be theoretically aligned. If misalignment is detected, a re-calibration procedure can be initiated by theprocessor1562.
• Theexample renderer program1580eis configured to render the left and right views for circular polarization. However, in other embodiments, therenderer program1580emay provide a stereoscopic image compatible with linear polarization. Regardless of which type of polarization is used, theexample processor1562 may execute aprogram1560 to verify or check a polarity of the stereoscopic images being output by therenderer program1580e. To check polarity, theprocessor1562 and/or the peripheralinput unit interface1574 inserts diagnostic data into the left and/or right images. For example, theprocessor1562 and/or the peripheralinput unit interface1574 may overlay “left” text onto the left image and “right” text onto the right image. Theprocessor1562 and/or the peripheralinput unit interface1574 may display a prompt instructing an operator to close one eye at a time while wearing theglasses1712 to confirm the left view is being received at the left eye and the right view is being received at the right eye. The operator may provide confirmation via theuser input device1410 indicating whether the polarization is correct. If the polarization is not correct, theexample renderer program1580eis configured to reverse locations where the left and right images are inserted into the combined stereoscopic image.
• In yet other embodiments, theexample renderer program1580eis configured to provide for frame sequential projection instead of creating a combined stereoscopic image. Here, therenderer program1580erenders the left images and or frames time-sequentially interleaved with the right images and/or frames. Accordingly the left and right images are alternately presented to thesurgeon504. In these other embodiments, thescreen1702 is not polarized. Instead, the left and right lenses of theglasses1712 may be electronically or optically synchronized to their respective portion of a frame sequence, which provides corresponding left and right views to a user to discern depth.
• In some examples, therenderer program1580emay provide certain of the right and left images for display on separate display monitors or separate windows on one display monitor. Such a configuration may be especially beneficial when lenses of right and left optical paths of theoptical elements1402 are independently adjustable. In an example, a right optical path may be set a first magnification level while a left optical path is set at a second magnification level. Theexample renderer program1580emay accordingly display a stream of images from the left view on thedisplay monitor512 and a stream of images from the right view on thedisplay monitor514. In some instances, the left view may be displayed in a first window on the display monitor512 while the right view is displayed in a second window (e.g., a picture-in-picture) of thesame display monitor512. Thus, while not stereoscopic, the concurrent display of the left and right images provides useful information to a surgeon.
• In another example, the light sources708 and thefilter740 may be switched quickly to generate alternating images with visible light and fluorescent light. Theexample renderer program1580emay combine the left and right views to provide a stereoscopic display under different lighting sources to highlight, for example, a vein with a dye agent while showing the background in visible light.
• In yet another example, a digital zoom may be applied to the right and/or leftoptical image sensor746 or748. Digital zoom generally affects the perceived resolution of the image and is dependent on factors such as the display resolution and the preference of the viewer. For example, theprocessor1504 of theimage capture module1404 may apply digital zooming by creating interpolated pixels synthesized and interspersed between the digitally-zoomed pixels. Theprocessor1504 may operate aprogram1510 that coordinates the selection and interpolation pixels for theoptical image sensors746 and748. Theprocessor1504 transmits the right and left images with digital zoom applied to theinformation processor module1408 for subsequent rendering and display.
• In some embodiments, theprocessor1504 receives instructions from theprocessor1562 that a digital zoom image is to be recorded between images without digital zoom to provide a picture-in-picture (or separate window) display of a digital zoom of a region of interest of thetarget site700. Theprocessor1504 accordingly applies digital zooming to every other read from thepixel grids1002 and1004. This enables therenderer program1580eto display simultaneously a stereoscopic full resolution image in addition to a digitally-zoomed stereoscopic image. Alternatively, the image to be zoomed digitally is copied from the current image, scaled, and placed during the render phase in the proper position overlaid atop the current image. This alternatively configuration avoids the “alternating” recording requirement.
6. Calibration Example
• The exampleinformation processor module1408 ofFIGS. 14 to 16 may be configured to execute one ormore calibration programs1560 to calibrate, for example, a working distance and/or magnification. For example, theprocessor1562 may send instructions to the motor andlighting module1406 to perform a calibration step for mapping a working distance (measured in millimeters) from the mainobjective assembly702 to thetarget site700 to a known motor position of the workingdistance lens motor1554. Theprocessor1562 performs the calibration by sequentially moving an object plane in discrete steps along the optical axis and re-focusing the left and right images, while recording encoder counts and the working distance. In some examples, the working distance may be measured by an external device, which transmits the measured working distance values to theprocessor1562 via the peripheralinput unit interface1574 and/or an interface to theuser input device1410. Theprocessor1562 may store the position of the rear working distance lens704 (based on position of the working distance lens motor1554) and the corresponding working distance.
• Theexample processor1562 may also execute aprogram1560 to perform magnification calibration. Theprocessor1562 may set theoptical elements1402, using the motor andlighting module1406 to select magnification levels. Theprocessor1562 may record positions of theoptical elements1402, or corresponding motor positions with respect to each magnification level. The magnification level may be determined by measuring a height in an image of an object of a known size. For example, theprocessor1562 may measure an object as having a height of 10 pixels and use a look-up-table to determine that a 10 pixel height corresponds to a 5× magnification.
• To match the stereoscopic perspectives of two different imaging modalities it is often desirable to model them both as if they are simple pinhole cameras. The perspective of a 3D computer model, such as a MM brain tumor, can be viewed from user-adjustable directions and distances (e.g. as if the images are recorded by a synthesized stereoscopic camera). The adjustability can be used to match the perspective of the live surgical image, which must therefore be known. Theexample processor1562 may calibrate one or more of these pinhole camera model parameters such as, for example, a center of projection (“COP”) of the right and leftoptical image sensors746 and748. To determine center of projection, theprocessor1562 determines a focus distance from the center of projection to an object plane. First, theprocessor1562 sets theoptical elements1402 at a magnification level. Theprocessor1562 then records measurements of a height of an image at three different distances along the optical axis including at the object plane, a distance d less than the object plane distance, and a distance d greater than the object plane distance. Theprocessor1562 uses an algebraic formula for similar triangles at the two most extreme positions to determine the focus distance to the center of projection. Theprocessor1562 may determine focus distances at other magnifications using the same method or by determining a ratio between the magnifications used for calibration. The processor may use a center of projection to match the perspective of an image of a desired fusion object, such as an MRI tumor model, to a live stereoscopic surgical image. Additionally or alternatively, existing camera calibration procedures such as OpenCV calibrateCamera may be used to find the above-described parameters as well as additional camera information such as a distortion model for theoptical elements1402.
• Theexample processor1562 may further calibrate the left and right optical axes. Theprocessor1562 determines an interpupillary distance between the left and right optical axes for calibration. To determine the interpupillary distance, theexample processor1562 records left and right images where pixel sets1006 and1008 are centered at thepixel grids1002 and1004. Theprocessor1562 determines locations of ZRPs (and/or distances to a displaced object) for the left and right images, which are indicative of image misalignment and degree of parallax. In addition, theprocessor1562 scales the parallax and/or the distance based on the magnification level. Theprocessor1562 then determines the interpupillary distance using a triangulation calculation taking into account the degree of parallax and/or the scaled distance to the object in the display. Theprocessor1562 next associates the interpupillary distance with the optical axis at the specified magnification level as a calibration point.
VI. Image Alignment and Spurious Parallax Adjustment Embodiment
• Similar to human vision, stereoscopic images comprise right views and left views that converge at a point of interest. The right and left views are recorded at slightly different angles from the point of interest, which results in parallax between the two views. Items in the scene in front of or behind the point of interest exhibit parallax such that distance or depth of the items from the viewer can be deduced. The accuracy of the perceived distance is dependent on, for example, the clarity of the viewer's eyesight. Most humans exhibit some level of imperfection in their eyesight, resulting in some inaccuracies between the right and left views. However, they are still able to achieve stereopsis, with the brain fusing the views with some level of accuracy.
• When left and right images are recorded by a camera instead of being viewed by a human, the parallax between the combined images on a display screen produces stereopsis, which provides an appearance of a three-dimensional stereoscopic image on a two-dimensional display. Errors in the parallax can affect the quality of the three-dimensional stereoscopic image. The inaccuracy of the observed parallax in comparison to a theoretically perfect parallax is known as spurious parallax. Unlike humans, cameras do not have brains that automatically compensate for the inaccuracies.
• If spurious parallax becomes significant, the three-dimensional stereoscopic image may be unviewable to the point of inducing vertigo, headaches, and nausea. There are many factors that can affect the parallax in a microscope and/or camera. For instance, optical channels of the right and left views may not be exactly equal. The optical channels may have unmatched focus, magnification, and/or misalignment of points of interest. These issues may have varying severity at different magnifications and/or working distances, thereby reducing efforts to correct through calibration.
• Known surgical microscopes, such as thesurgical microscope200 ofFIG. 2 are configured to provide an adequate view through theoculars206. Often, the image quality of optical elements of known surgical microscopes is not sufficient for stereoscopic cameras. The reason for this is because manufacturers of surgical microscopes assume the primary viewing is through oculars. Any camera attachment (such as the camera212) is either monoscopic and not subject to spurious parallax or stereoscopic with low image resolution where spurious parallax is not as apparent.
• International standards, such as ISO 10936-1:2000, Optics and optical instruments—Operation microscopes—Part1: Requirements and test methods, have been developed to provide specification limits for image quality of surgical microscopes. The specification limits are generally set for viewing through the oculars of a surgical microscope and do not consider three-dimensional stereoscopic display. For example, regarding spurious parallax, ISO 10936-1:2000 specifies that the difference in vertical axes between the left and right views should be less than 15 arc-minutes. Small angular deviations of axes are often quantified in arc-minutes, which corresponds to 1/60^thof a degree, or arc-seconds, which corresponds to 1/60^thof an arc-minute. The 15 arc-minute specification limit corresponds to a 3% difference between left and right views for a typical surgical microscope with a working distance of 250 mm and a field-of-view of 35 mm (which has an angular field-of-view of 8°).
• The 3% difference is acceptable for ocular viewing where a surgeon's brain is able to overcome the small degree of error. However, this 3% difference produces noticeable differences between left and right views when viewed stereoscopically on a display monitor. For example, when the left and right views are shown together, a 3% difference results in an image that appears disjointed and difficult to view for extended periods of time.
• Another issue is that known surgical microscopes may satisfy the 15 arc-minute specification limit at only one or a few magnification levels and/or only individual optical elements may satisfy a certain specification limit. For example, individual lenses are manufactured to meet certain criteria. However, when the individual optical elements are combined in an optical path, small deviations from the standard may be amplified rather than canceled. This can be especially pronounced when five or more optical elements are used in an optical path including a common main objective lens. In addition, it is very difficult to perfectly match optical elements on parallel channels. At most, during manufacture, the optical elements of a surgical microscope are calibrated only at one or a few certain magnification levels to meet the 15 arc-minute specification limit. Accordingly, the error may be greater between the calibration points despite the surgical microscope allegedly meeting the ISO 10936-1:2000 specifications.
• In addition, the ISO 10936-1:2000 specification permits larger tolerances when additional components are added. For example, adding second oculars (e.g., the oculars208) increases the spurious parallax by 2 arc-minutes. Again, while this error may be acceptable for viewing throughoculars206 and208, image misalignment becomes more pronounced when viewed stereoscopically through the camera.
• In comparison to known surgical microscopes, the examplestereoscopic visualization camera300 disclosed herein is configured to automatically adjust at least some of theoptical elements1402 to reduce or eliminate spurious parallax. Embedding the optical elements within thestereoscopic visualization camera300 enables fine adjustments to be made automatically (sometimes in real-time) for three-dimensional stereoscopic display. In some embodiments, the examplestereoscopic visualization camera300 may provide an accuracy of 20 to 40 arc-seconds, which is close to a 97% reduction in optical error compared to the 15 arc-minute accuracy of known surgical microscopes.
• The improvement in accuracy enables the examplestereoscopic visualization camera300 to provide features that are not capable of being performed with known stereoscopic microscopes. For example, many new microsurgical procedures rely on accurate measurements in a live surgical site for optimal sizing, positioning, matching, directing, and diagnosing. This includes determining a size of a vessel, an angle of placement of a toric Intra Ocular Lens (“IOL”), a matching of vasculature from a pre-operative image to a live view, a depth of a tumor below an artery, etc. The examplestereoscopic visualization camera300 accordingly enables precise measurements to be made using, for example, graphical overlays or image analysis to determine sizes of anatomical structures.
• Known surgical microscopes require that a surgeon place an object of a known size (such as a micro-ruler) into the field-of-view. The surgeon compares the size of the object to surrounding anatomical structure to determine an approximate size. However, this procedure is relatively slow since the surgeon has to place the object in the proper location, and then remove it after the measurement is performed. In addition, the measurement only provides an approximation since the size is based on the surgeon's subjective comparison and measurement. Some known stereoscopic cameras provide graphical overlays to determine size. However, the accuracy of these overlays is reduced if spurious parallax exists between the left and right views.
A. ZRP as a Source of Spurious Parallax
• ZRP inaccuracy provides a significant source of error between left and right images resulting in spurious parallax. ZRP, or zoom repeat point, refers to a point in a field-of-view that remains in a same location as a magnification level is changed.FIGS. 18 and 19 show examples of ZRP in a left and right field-of-view for different magnification levels. Specifically,FIG. 18 shows a left field-of-view1800 for a low magnification level and a left field-of-view1850 for a high magnification level In addition,FIG. 19 shows a right field-of-view1900 for a low magnification level and a right field-of-view1950 for a high magnification level.
• It should be noted thatFIGS. 18 and 19 show crosshairs1802 and1902 to provide an exemplary point of reference for this disclosure. The crosshairs1802 include afirst crosshair1802apositioned along a y-direction or y-axis and asecond crosshair1802bpositioned along an x-direction or x-axis. Additionally, crosshairs1902 include afirst crosshair1902apositioned along a y-direction or y-axis and asecond crosshair1902bpositioned along an x-direction or x-axis In actual implementation, the examplestereoscopic visualization camera300 by default typically does not include or add crosshairs to the optical path unless requested by an operator.
• Ideally, the ZRP should be positioned at a central location or origin point. For example, the ZRP should be centered in the crosshairs1802 and1902. However, inaccuracies in theoptical elements1402 and/or slight misalignments between theoptical elements1402 cause the ZRP to be located away from the center of the crosshairs1802 and1902. The degree of spurious parallax corresponds to how far each of the ZRPs of the left and right views is located away from the respective centers in addition to ZRPs being misaligned between the left and right views. Moreover, inaccuracies in theoptical elements1402 may cause the ZRP to drift slightly as magnification changes, thereby further causing a greater degree of spurious parallax.
• FIG. 18 shows three crescent-shapedobjects1804,1806, and1808 in the field-of-views1800 and1850 of thetarget site700 ofFIG. 7. It should be appreciated that the field-of-views1800 and1850 are linear field-of-views with respect to theoptical image sensors746 and748. Theobjects1804,1806, and1808 were placed in the field-of-view1800 to illustrate how spurious parallax is generated from left and right image misalignment. Theobject1804 is positioned abovecrosshair1802balong crosshair1802a. Theobject1806 is positioned alongcrosshair1802band to the left of thecrosshair1802a. Theobject1808 is positioned slightly below thecrosshair1802band to the right of thecrosshair1802a. AZRP1810 for the left field-of-view1800 is positioned in a notch of theobject1808.
• The left field-of-view1800 is changed to the left field-of-view1850 by increasing the magnification level (e.g., zooming) using thezoom lens assembly716 of the examplestereoscopic visualization camera300. Increasing the magnification causes theobjects1804,1806, and1808 to appear to expand or grow, as shown in the field-of-view1850. In the illustrated example, the field-of-view1850 is approximately 3× the magnification level of the field-of-view1800.
• Compared to the low magnification field-of-view1800, theobjects1804,1806, and1808 in high magnification field-of-view1850 have increased in size by about 3× while also moving apart from each other by3X with respect to theZRP1810. In addition, the positions of theobjects1804,1806, and1808 have moved relative to the crosshairs1802. Theobject1804 is now shifted to the left of thecrosshair1802aand shifted slightly further from thecrosshair1802b. In addition, theobject1806 is now shifted further to the left of crosshair1802aand slightly above thecrosshair1802b. Generally, theobject1808 is located in the same (or nearly the same) position with respect to the crosshairs1802, with theZRP1810 being located in the exact same (or nearly the same) position with respect to the crosshairs1802 and theobject1806. In other words, as magnification increases, theobjects1804,1806, and1808 (and anything else in the field-of-view1850) appear to move away and outward from theZRP1810.
• Thesame objects1804,1806, and1808 are shown in the right field-of-views1900 and1950 illustrated inFIG. 19. However, the location of the ZRP is different. Specifically,ZRP1910 is located above crosshair1902band to the left of crosshair1902ain the right field-of-views1900 and1950. Thus, theZRP1910 is located at a different location than theZRP1810 in the left field-of-views1800 and1850. In the illustrated example, it is assumed that the left and right optical paths are perfectly aligned at the first magnification level. Accordingly, theobjects1804,1806, and1808 shown in the right field-of-view1900 in the same location as thesame objects1804,1806, and1808 in the left field-of-view1800. Since the left and right views are aligned, no spurious parallax exists.
• However, in the high magnification field-of-view1950, theobjects1804,1806, and1808 expand and move away from theZRP1910. Given the location of theZRP1910, theobject1804 moves or shifts to the right and theobject1806 moves or shifts downward. In addition, theobject1808 moves downward and to the right compared to its location in the field-of-view1900.
• FIG. 20 shows a pixel diagram comparing the high magnification left field-of-view1850 to the high magnification right field-of-view. Agrid2000 may represent locations of the objects1804(L),1806(L), and1808(L) on thepixel grid1004 of the leftoptical image sensor748 overlaid with locations of the objects1804(R),1806(R), and1808(R) on thepixel grid1002 of the leftoptical image sensor746.FIG. 20 clearly shows that theobjects1804,1806, and1808 are in different positions for the left and right field-of-views1850 and1950. For example, the object1804(R) is located to the right ofcrosshair1902aand abovecrosshair1902bwhile the same object1804(L) is located to the left ofcross hair1802aand further abovecross hair1802b.
• The difference in positions of theobjects1804,1806, and1808 corresponds to spurious parallax, which is created by deficiencies in the optical alignment of theoptical elements1402 that produce ZRPs1810 and1910 in different locations. Assuming no distortion or other imaging errors, the spurious parallax shown inFIG. 20 is generally the same for all points within the image. When viewed through oculars of a surgical microscope (such asmicroscope200 ofFIG. 2), the difference in location of theobjects1804,1806, and1808 may not be noticeable. However, when viewed on the display monitors512 and514 in a stereoscopic image, the differences become readily apparent and can result in headaches, nausea, and/or vertigo.
• FIG. 21 shows a diagram illustrative of spurious parallax with respect to left and right ZRPs. The diagram includes apixel grid2100 that includes overlays of the right and leftpixel grids1002 and1004 ofFIG. 10. In this illustrated example, aleft ZRP2102 for the left optical path is located at +4 along the x-axis and 0 along the y-axis. In addition, aright ZRP2104 for the right optical path is located at −1 along the x-axis and 0 along the y-axis. Anorigin2106 is shown at the intersection of the x-axis and the y-axis.
• In this example,object2108 is aligned with respect to the left and right images at a first low magnification. As magnification is increased by 3×, theobject2108 increased in size and moved away from theZRPs2102 and2104. Outlines object2110 shows a theoretical location of theobject2108 at the second higher magnification based on theZRPs2102 and2104 being aligned with theorigin2106. Specifically, a notch of theobject2108 at the first magnification level is at location +2 along the x-axis. With 3× magnification, the notch moves3X along the x-axis such that the notch is located at +6 along the x-axis at the higher magnification level. In addition, since the ZRPs2102 and2104 would be theoretically aligned at theorigin2106, theobject2110 would be aligned between the left and right views (shown inFIG. 21 as a single object given the overlay).
• However, in this example, misalignment of the left and right ZRPs2102 and2104 causes theobject2110 to be misaligned between the left and right views at higher magnification. Regarding the right optical path, theright ZRP2104 is located at −1 along the x-axis such that it is 3 pixels away from the notch of theobject2108 at low magnification. When magnified 3×, this difference becomes 9 pixels, which is shown as object2110(R). Similarly, theleft ZRP2102 is located at +4 pixels along the x-axis. At 3× magnification, theobject2108 moves from being 2 pixels away to 6 pixels away, which is shown as object2110(L) at −2 along the x-axis.
• The difference in positions of the object2110(L) and the object2110(R) corresponds to the spurious parallax between the left and right views at the higher magnification. If the right and left views were combined into a stereoscopic image for display, the location of theobject2110 would be misaligned at each row if the renderer program1850euses a row-interleaved mode. The misalignment would be detrimental to generating stereopsis and may produce an image that appears blurred or confusing to an operator.
B. Other Sources of Spurious Parallax
• While ZRP misalignment between left and right optical paths is a significant source of spurious parallax, other sources of error also exist. For example, spurious parallax may result from non-equal magnification changes between the right and left optical paths. Differences in magnification between parallel optical paths may result from slight variances in the optical properties or characteristics of the lenses of theoptical elements1402. Further, slight differences may result from positioning if each of the left and rightfront zoom lenses726 and728 and each of the left and rightrear zoom lenses736 and738 ofFIGS. 7 and 8 are independently controlled.
• Referring back toFIGS. 18 and 19, differences in magnification change produce differently sized objects and different spacing between the objects for the left and right optical paths. If, for example, the left optical path has a higher magnification change, then theobjects1804,1806, and1808 will appear larger and move a greater distance from theZRP1810 compared to theobjects1804,1806, and1808 in the right field-of-view1950 inFIG. 19. The difference in the location of theobjects1804,1806, and1808, even if theZRPs1810 and1910 are aligned, results in spurious parallax.
• Another source of spurious parallax results from unequal focusing of the left and right optical paths. Generally, any difference in focus between left and right views may cause a perceived diminishment in image quality and potential confusion over whether the left or right view should predominate. If the focus difference is noticeable, it can result in an Out-Of-Focus (“OOF”) condition. OOF conditions are especially noticeable in stereoscopic images where left and right views are shown in the same image. In addition, OOF conditions are not easily correctable since re-focusing an out-of-focus optical path usually results in the other optical path becoming unfocused. Generally, a point needs to be determined where both optical paths are in focus, which may include changing positions of left and right lenses along an optical path and/or adjusting a working distance from thetarget site700.
• FIG. 22 shows a diagram illustrative of how an OOF condition develops. The diagram relates perceived resolution (e.g., focus) to a lens position relative to anoptimal resolution section2202. In this example the leftrear zoom lens734 is at position L1 while the rightrear zoom lens732 is at position R1. At position L1 and R1, therear zoom lenses732 and734 are in a range ofoptimal resolution2202 such that the left and right optical paths have matched focus levels. However, there is a difference in the positions of L1 and R1, corresponding to distance ΔP. At a later time, the workingdistance706 is changed such that a point is out-of-focus. In this example, bothrear zoom lenses732 and734 move the same distance to locations L2 and R2 such that distance ΔP does not change. However, the position change results in a significant change in resolution ΔR such that the leftrear zoom lens734 has a higher resolution (e.g., better focus) that the rightrear zoom lens732. The resolution ΔR corresponds to the OOF condition, which results in spurious parallax from misalignment of focus between the right and left optical paths.
• Yet another source of spurious parallax can result from imaging objects that are moving at thetarget site700. The spurious parallax results from small synchronization errors between exposures of the right and leftoptical image sensors746 and748. If the left and right views are not recorded simultaneously, then the object appears to be displaced or misaligned between the two views. The combined stereoscopic image shows the same object at two different locations for the left and right views.
• Moreover, another source of spurious parallax involves a moving ZRP point during magnification. The examples discussed above in Section IV(A) assume that the ZRPs of the left and right views do not move in the x-direction or the y-direction. However, the ZRPs may shift during magnification if thezoom lenses726,728,732, and/or734 do not move exactly parallel with the optical path or axis (e.g., in the z-direction). As discussed above in reference toFIG. 11, thecarrier724 may shift or rotate slightly when a force is applied to theactuation section1108. This rotation may cause the left and right ZRPs to move slightly when a magnification level is changed.
• In an example, during a magnification change, thecarrier730 moves in a single direction while thecarrier724 moves in the same direction for a portion of the magnification change and in an opposite direction for a remaining portion of the magnification change for focus adjustment. If the axis of motion of thecarrier724 is tilted or rotated slightly with respect to the optical axis, the ZRP of the left and/or right optical paths will shift in one direction for the first portion followed by a shift in a reverse direction for the second portion of the magnification change. In addition, since the force is applied unequally, the right and leftfront zoom lenses726 and728 may experience varying degrees of ZRP shift between the left and right optical paths. Altogether, the change in position of the ZRP results in misaligned optical paths, thereby producing spurious parallax.
C. Reduction in Spurious Parallax Facilitates Incorporating Digital Graphics and Images with a Stereoscopic View
• As surgical microscopes become more digitalized, designers are adding features that overlay graphics, images, and/or other digital effects to the live-view image. For example, guidance overlays, fusion of stereoscopic Magnetic Resonance Imaging (“MRI”) images, and/or external data may be combined with images recorded by a camera, or even displayed within oculars themselves. Spurious parallax reduces the accuracy of the overlay with the underlying stereoscopic image. Surgeons generally require, for example, that a tumor visualized via MRI be placed as accurately as possible, often in three dimensions, within a fused live surgical stereoscopic view. Otherwise, the preoperative tumor image provides little information to the surgeon, thereby detracting from the performance.
• For example, a surgical guide may be aligned with a right view image while misaligned with the left view. The misaligned surgical guide between the two views is readily apparent to the operator. In another example, a surgical guide may be aligned separately with left and right views in theinformation processor module1408 prior to thegraphics processing unit1564 creating the combined stereoscopic image. However, misalignment between the left and right views creates misalignment between the guides, thereby reducing the effectiveness of the guides and creating confusion and delay during the microsurgical procedure.
• U.S. Pat. No. 9,552,660, titled “IMAGING SYSTEM AND METHODS DISPLAYING A FUSED MULTIDIMENSIONAL RECONSTRUCTED IMAGE,” (incorporated herein by reference) discloses how preoperative images and/or graphics are visually fused with a stereoscopic image.FIGS. 23 and 24 show diagrams that illustrate how spurious parallax causes digital graphics and/or images to lose accuracy when fused to a stereoscopic image.FIG. 24 shows a front view of a patient'seye2402 andFIG. 23 shows a cross-sectional view of the eye along plane A-A ofFIG. 24. InFIG. 23, theinformation processor module1408 is instructed to determine a caudal distance d from afocus plane2302 to, for example, an object ofinterest2304 on a posterior capsule of theeye2402. Theinformation processor module1408 operates aprogram1560 that specifies, for example, that the distance d is determined by a triangulation calculation of image data from the left and right views of theeye2402. Aview2306 is shown from a perspective of the leftoptical image sensor748 and aview2308 is shown from a perspective of the rightoptical image sensor746. The left andright views2306 and2308 are assumed to be coincident with ananterior center2310 of theeye2402. In addition, the left andright views2306 and2308 are two-dimensional views of theobject2304 projected onto afocal plane2302 astheoretical right projection2312 and theoreticalleft projection2314. In this example,processor1562 determines the distance d to the object ofinterest2304 by calculating an intersection of an extrapolation of thetheoretical right projection2312 and an extrapolation of the theoreticalleft projection2314 using a triangulation routine.
• However, in this example spurious parallax exists, which causes an actualleft projection2316 to be located to the left of the theoreticalleft projection2314 by a distance P, as shown inFIGS. 23 and 24. Theprocessor1562 uses the actualleft projection2316 and theright projection2312 to determine a distance to anintersection2320 of an extrapolation of theright projection2312 and an extrapolation of the actualleft projection2316 using the triangulation routine. The distance of theintersection point2320 is equal to the distance d plus an error distance e. The spurious parallax accordingly results in an erroneous distance calculation using data taken from a stereoscopic image. As shown inFIGS. 23 and 24, even a small degree of spurious parallax may create a significant error. In the context of a fused image, the erroneous distance may result in an inaccurate placement of a tumor three-dimensional visualization for fusion with a stereoscopic image. The inaccurate placement may delay the surgery, hinder the performance of the surgeon, or cause the entire visualization system to be disregarded. Worse yet, a surgeon may rely on the inaccurate placement of the tumor image and make a mistake during the microsurgery procedure.
D. The Example Stereoscopic Visualization Camera Reduces or Eliminates Spurious Parallax
• The examplestereoscopic visualization camera300 ofFIGS. 3 to 16 is configured to reduce or eliminate visual defects, spurious parallax, and/or misaligned optical paths that typically result in spurious parallax. In some examples, thestereoscopic visualization camera300 reduces or eliminates spurious parallax by aligning ZRPs of the left and right optical paths to the respective centers of pixel sets1006 and1008 of the right and leftoptical image sensors746 and748. Additionally or alternatively, thestereoscopic visualization camera300 may align the optical paths of the left and right images. It should be appreciated that thestereoscopic visualization camera300 may perform actions to reduce spurious parallax during calibration. Additionally, thestereoscopic visualization camera300 may reduce detected spurious parallax in real-time during use.
• FIGS. 25 and 26 illustrate a flow diagram showing anexample procedure2500 to reduce or eliminate spurious parallax, according to an example embodiment of the present disclosure. Although theprocedure2500 is described with reference to the flow diagram illustrated inFIGS. 25 and 26, it should be appreciated that many other methods of performing the steps associated with theprocedure2500 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure2500 may be performed among multiple devices including, for example theoptical elements1402, theimage capture module1404, the motor andlighting module1406, and/or theinformation processor module1408 of the examplestereoscopic visualization camera300. For example, theprocedure2500 may be performed by one of theprograms1560 of theinformation processor module1408.
• Theexample procedure2500 begins when thestereoscopic visualization camera300 receives an instruction to align right and left optical paths (block2502). The instructions may be received from theuser input device1410 in response to an operator requesting that thestereoscopic visualization camera300 perform a calibration routine. In other examples, the instructions may be received from theinformation processor module1408 after determining right and left images are misaligned. Theinformation processor module1408 may determine images are not aligned by executing aprogram1560 that overlays right and left images and determines differences in pixel values, where greater differences over large areas of pixels are indicative of misaligned images. In some examples, theprogram1560 may compare the pixel data of the left and right images without performing an overlay function, where, for example, left pixel data is subtracted from right pixel data to determine a severity of misalignment.
• After receiving instructions to reduce spurious parallax, the examplestereoscopic visualization camera300 locates a ZRP of one of the left or right optical path. For illustrative purposes,procedure2500 includes the ZRP of the left optical path being determined first. However, in other embodiments, theprocedure2500 may determine the ZRP of the right optical path first. To determine the left ZRP, thestereoscopic visualization camera300 moves at least one zoom lens (e.g., the leftfront zoom lens728 and/or the left rear zoom lens734) to a first magnification level along a z-direction of the left optical path (block2504). In instances where thefront zoom lenses726 and728 are connected to thesame carrier724 and therear zoom lenses732 and734 are connected to thesame carrier730, the movement of the left lenses causes the right lenses to also move. However, only movement of the left lenses is considered during this section of theprocedure2500.
• At the first magnification level, thestereoscopic visualization camera300 causes the left zoom lens to move along the z-direction (block2506). The movement may include, for example, back-and-forth movement around the first magnification level. For example, if the first magnification level is 5×, the movement may be between 4× and 6×. The movement may also include movement in one direction, such as from 5× to 4×. During this movement, thestereoscopic visualization camera300 may adjust one or more other lenses to maintain focus of thetarget site700. Atblock2508, during the movement of the left zoom lens, thestereoscopic visualization camera300 records a stream or a sequence of images and/orframes2509 of thetarget site700 using, for example, the leftoptical image sensor748. Theimages2509 are recorded using an oversized pixel set1008 configured to encompass an origin of thepixel grid1004 and potential locations of the left ZRP.
• Theexample processor1562 of theinformation processor module1408 analyzes the image stream to locate a portion of area that does not move in an x-direction or a y-direction between the images (block2510). The portion of the area may include one or a few pixels and corresponds to the left ZRP. As discussed above, during a magnification change, objects move away from the ZRP or move towards the ZRP. Only objects at the ZRP remain constant in position with respect to the field-of-view as magnification changes. Theprocessor1562 may calculate deltas between the stream of images for each pixel using pixel data. An area with the smallest delta across the image stream corresponds to the left ZRP.
• Theexample processor1562 of theinformation processor module1408 next determines coordinates of a portion of the area that does not move between the image stream (e.g., determines a location of the left ZRP) with respect to the pixel grid1004 (block2512). In other examples, theprocessor1562 of theinformation processor module1408 determines a distance between the origin and the portion of the area corresponding to the left ZRP. The distance is used to determine a position of the left ZRP on thepixel grid1004. Once the location of the left ZRP is determined, theprocessor1562 of theinformation processor module1408 determines a pixel set (e.g., the pixel set1008) for the leftoptical image sensor748 such that the left ZRP is located at a center (within one pixel) of the pixel set (block2514). At this point, the left ZRP is centered within the left optical path.
• In some examples, blocks2504 to2514 may be performed iteratively by re-selecting the pixel set until the left ZRP is within a pixel of the origin and spurious parallax is minimized. After the pixel grid is determined, theprocessor1562 of theinformation processor module1408 stores at least one of coordinates of the pixel set and/or coordinates of the left ZRP to thememory1570 as a calibration point (block2516). Theprocessor1562 of theinformation processor module1408 may associate the first magnification level with the calibration point such that the same pixel set is selected when thestereoscopic visualization camera300 returns to the first magnification level.
• FIG. 27 shows a diagram illustrative of how the left ZRP is adjusted with respect to the pixel grid of the leftoptical image sensor748. Initially, an initial (e.g., oversized)pixel set2702 is selected, which is centered onorigin2704. The pixel set2702 is large enough to record potential ZRPs in the image stream. In this illustrated example, aleft ZRP2706 is located above and to the right of theorigin2704. Theprocessor1562 of theinformation processor module1408 determines pixel set2708 based on a location of theleft ZRP2706 such that theleft ZRP2706 is located or positioned at a center of thepixel set2708.
• After the left ZRP is determined and aligned with an origin of a pixel set inFIG. 25, theexample procedure2500 aligns the left and right images inFIG. 26. To align the images, theexample processor1562 compares pixel data from left and right images recorded after the left ZRP is aligned with the origin. In some embodiments, theprocessor1562 overlays the left and right images to determine differences using, for example, a subtraction and/or template method. Theprocessor1562 selects or determines a pixel set for the right optical path such that the resulting right images align or coincide with the left images (block2519).
• Theexample processor1562, in the illustrated embodiment, determines the right ZRP. The steps are similar to steps discussed inblocks2504 to2512 for the left ZRP. For example, atblock2518 thestereoscopic visualization camera300 moves a right zoom lens to the first magnification level. In some embodiments, the magnification level for the right lens is different than the magnification level used for determining the left ZRP. Theexample processor1562 of theinformation processor module1408 then moves the right zoom lens around the magnification level and receives a stream ofimages2521 from the rightoptical image sensor746 during the movement (blocks2520 and2522). Theexample processor1562 of theinformation processor module1408 determines the right ZRP from the right stream of images by locating a portion of an area that does not move between the images (block2524). Theprocessor1562 next determines coordinates of the right ZRP and/or a distance between a center of an aligned pixel set1006 to the right ZRP (block2526).
• Theprocessor1562 then instructs the motor andlighting module1406 to move at least one lens in the right optical path in at least one of an x-direction, a y-direction, and/or a tilt-direction to align the right ZRP with the center of the aligned pixel set1006 using, for example, the distance or coordinates of the right ZRP (block2528). In other words, the right ZRP is moved to coincide with the center of the alignedpixel set1006. In some examples, the rightfront lens720, theright lens barrel736, the right finaloptical element745, and/or theright image sensor746 is moved (using for example a flexure) in the x-direction, the y-direction and/or a tilt-direction with respect to the z-direction of the right optical path. The degree of movement is proportional to the distance of the right ZRP from the center of thepixel set1006. In some embodiments, theprocessor1562 digitally changes properties of the rightfront lens720, theright lens barrel736, and/or the right finaloptical element745 to have the same effect as moving the lenses. Theprocessor1562 may repeatsteps2520 to2528 and/or use subsequent right images to confirm the right ZRP is aligned with the center of thepixel set1006 and/or to iteratively determine further lens movements needed to align the right ZRP with the center of the pixel set.
• Theexample processor1562 stores coordinates of the right pixel set and/or the right ZRP to thememory1570 as a calibration point (block2530). Theprocessor1562 may also store to the calibration point a position of the right lens that was moved to align the right ZRP. In some examples, the calibration point for the right optical path is stored with the calibration point for the left optical path in conjunction with the first magnification level. Thus, theprocessor1562 applies the data within the calibration point to theoptical image sensors746 and748 and/or radial positioning of one or moreoptical elements1402 when thestereoscopic visualization camera300 is subsequently set to the first magnification level.
• In some examples, theprocedure2500 may be repeated for different magnification levels and/or working distances. Accordingly, theprocessor1562 determines if ZRP calibration is needed for another magnification level or working distance (block2532). If another magnification level is to be selected, theprocedure2500 returns to block2504 inFIG. 25. However, if another magnification level is not needed, the example procedure ends.
• Each of the calibration points may be stored in a look-up-table. Each row in the table may correspond to a different magnification level and/or working distance. Columns in the look-up-table may provide coordinates for the left ZRP, the right ZRP, the left pixel set, and/or the right pixel set. In addition, one or more columns may specify relevant positions (e.g., radial, rotational, tilt, and/or axial positions) of the lenses of theoptical elements1402 to achieve focus at the magnification level in addition to aligned right and left images.
• Theprocedure2500 accordingly results in the right ZRP and the left ZRP in addition to views of the target site to be aligned to pixel grids of the respectiveoptical image sensors746 and748 as well as to each other in a three-dimensional stereoscopic image. In some instances, the left and right images and the corresponding ZRPs have an accuracy and alignment to within one pixel. Such accuracy may be observable on thedisplay514 or514 by overlaying left and right views (e.g., images from the left and right optical paths) and observing both views with both eyes, rather than stereoscopically.
• It should be appreciated that in some examples, a right pixel set is first selected such that the right ZRP is aligned with or coincident with an origin of the pixel set. Then, the right and left optical images may be aligned by moving one or more right and/or left lenses of theoptical elements1402. This alternative procedure still provides right and left ZRPs that are centered and aligned between each other and with respect to theoptical image sensors746 and748.
• Theprocedure2500 ultimately reduces or eliminates spurious parallax in thestereoscopic visualization camera300 throughout a full optical magnification range by ensuring left and right ZRPs remain aligned and the right and left images remain aligned. In other words, the dual optics of the right and leftoptical images sensors746 and748 are aligned such that parallax at a center of an image between the left and right optical paths is approximately zero at the focal plane. Additionally, the examplestereoscopic visualization camera300 is par focal across the magnification range, and par central across magnification and working distance ranges since the ZRP of each optical path has been aligned to a center of the respective pixel set. Accordingly, changing only the magnification will maintain a focus of thetarget site700 in bothoptical image sensors746 and748 while being trained on the same center point.
• Theabove procedure2500 may be performed at calibration before a surgical procedure is performed and/or upon request by an operator. Theexample procedure2500 may also be performed prior to image registration with a pre-operative microsurgical image and/or surgical guidance graphics. Further, theexample procedure2500 may be performed in real-time automatically during operation of thestereoscopic visualization camera300.
1. Template Matching Example
• In some embodiments, theexample processor1562 of theinformation processor module1408 is configured to use aprogram1560 in conjunction with one or more templates to determine a position of the right ZRP and/or the left ZRP.FIG. 28 shows a diagram illustrative of how theprocessor1562 uses atarget template2802 to determine a location of a left ZRP. In this example,FIG. 28 shows a first left image including thetemplate2802 aligned with anorigin2804 or center of theleft pixel grid1004 of the leftoptical image sensor748. Thetemplate2802 may be aligned by moving thestereoscopic visualization camera300 to the appropriate location. Alternatively, thetemplate2802 may be moved at thetarget site700 until aligned. In other examples, thetemplate2802 may include another pattern that does not need alignment with a center of thepixel grid1004. For example, the template may include a graphical wave pattern, a graphical spirograph pattern, a view of a surgical site of a patient and/or a grid having visually distinguishable features with some degree of non-periodicity in both the x and y-directions. The template is configured to prevent a subset of a periodic image from being perfectly aligned onto the larger image in a plurality of locations, which makes such templates unsuitable for matching. A template image that is suitable for template matching is known as a “template match-able” template image.
• Thetemplate2802 shown inFIG. 28 is imaged at a first magnification level. Aleft ZRP2806 is shown with respect to thetemplate2802. TheZRP2806 has coordinates of L_x, L_ywith respect to theorigin2804. However, at this point in time, theprocessor1562 has not yet identified theleft ZRP2806.
• To locate theZRP2806, theprocessor1562 causes a left zoom lens (e.g., the leftfront zoom lens728 and/or the left rear zoom lens734) to change magnification from the first magnification level to a second magnification level, specifically in this example, from 1× to 2×.FIG. 29 shows a diagram of a second left image including thetarget2802 on thepixel grid1004 with the magnification level doubled. From the first magnification level to the second magnification level, portions of thetarget2802 increase in size and expand uniformly away from theleft ZRP2806, which remains stationary with respect to the first and second images. In addition, a distance between theorigin2804 of thepixel grid1004 and theleft ZRP2806 remains the same.
• Theexample processor1562 synthesizes adigital template image3000 from the second image shown inFIG. 29. To create the digital template image, theprocessor1562 copies the second image shown inFIG. 29 and scales the copied image by the reciprocal of the magnification change from the first to the second magnification. For example, if the magnification change from the first image to the second image was by a factor of 2, then the second image is scaled by ½.FIG. 30 shows a diagram of thedigital template image3000, which includes thetemplate2802. Thetemplate2802 in thedigital template image3000 ofFIG. 30 is scaled to be the same size as thetemplate2802 in the first left image shown inFIG. 28.
• Theexample processor1562 uses thedigital template image3000 to locate theleft ZRP2806.FIG. 31 shows a diagram that shows thedigital template image3000 superimposed on top of the first left image (or a subsequent left image recorded at the first magnification level) recorded in thepixel grid1004. The combination of thedigital template image3000 with the first left image produces a resultant view, as illustrated inFIG. 31. Initially thedigital template image3000 is centered at theorigin2804 of thepixel grid1004.
• Theexample processor1562 compares thedigital template image3000 to theunderlying template2802 to determine if they are aligned or matched. Theexample processor1562 then moves thedigital template image3000 one or more pixels either horizontally or vertically and performs another comparison. Theprocessor1562 iteratively moves thedigital template image3000 compiling a matrix of metrics for each location regarding how close thedigital template image3000 matches theunderlying template2802. Theprocessor1562 selects the location in the matrix corresponding to the best matching metric. In some examples, theprocessor1562 uses the OpenCV™ Template Match function.
• FIG. 32 shows a diagram with thedigital template image3000 aligned with thetemplate2802. The distance that thedigital template image3000 was moved to achieve optimal matching is shown as Δx and Δy. Knowing thedigital template image3000 was synthesized at a scale of M1/M2 (the first magnification level divided by the second magnification level), theprocessor1562 determines the coordinates (L_x, L_y) of theleft ZRP2806 using Equations (1) and (2) below.
• 
  Lx=Δx/(M1/M2)  Equation (1)
• 
  Ly=Δy/(M1/M2)  Equation (2)
• After the coordinates (L_x, L_y) of theleft ZRP2806 are determined, theexample processor1562 selects or determines a pixel subset with an origin that is aligned or coincides with theleft ZRP2806, as discussed above in conjunction withprocedure2500 ofFIGS. 25 and 26. In some embodiments, theprocessor1562 may use template matching iteratively to converge on a highly accurate ZRP position and/or pixel subset. Further, while the above example discussed locating the left ZRP, the same template matching procedure can be used to locate the right ZRP.
• In some embodiments, the above-describedtemplate matching program1560 may be used to align the left and right images. In these embodiments, left and right images are recorded at a magnification level. Both the images may include, for example, thetarget template2802 ofFIG. 28. A portion of the right image is selected and overlaid with the left image. The portion of the right image is then shifted around the left image by one or more pixels horizontally and/or vertically. Theexample processor1562 performs a comparison at each location of the portion of the right image to determine how close a match exists with the left image. Once an optimal location is determined, apixel set1006 of theright pixel grid1002 is determined such that the right image is generally coincident with the left image. The location of thepixel set1006 may be determined based on how much the portion of the right image was moved to coincide with the left image. Specifically, theprocessor1562 uses an amount of movement in the x-direction, the y-direction, and/or the tilt-direction to determine corresponding coordinates for theright pixel set1006.
2. Right and Left Image Alignment Example
• In some embodiments, theexample processor1562 of theinformation processor module1408 ofFIGS. 14 to 16 displays an overlay of right and left images on thedisplay monitor512 and/or514. Theprocessor1562 is configured to receive user feedback for aligning the right and left images. In this example each pixel data for the right and left images is precisely mapped to a respective pixel of the display monitor512 using, for example, thegraphics processing unit1564. The display of overlaid left and right images makes any spurious parallax readily apparent to an operator. Generally, with no spurious parallax, the left and right images should almost exactly align.
• If an operator detects spurious parallax, the operator may actuate controls305 or theuser input device1410 to move either the right or left image for alignment with the other of the right and left image. Instructions from the controls305 may cause theprocessor1562 to accordingly adjust the location of the left or right pixel set in real-time, such that subsequent images are displayed on the display monitor512 reflective of the operator input. In other examples, the instructions may cause theprocessor1562 to change a position of one or more of theoptical elements1402 via radial adjustment, rotational adjustment, axial adjustment, or tilting. The operator continues to provide input via controls305 and/or theuser input device1410 until the left and right images are aligned. Upon receiving a confirmation instruction, theprocessor1562 stores a calibration point to a look-up-table reflective of the image alignment at the set magnification level.
• Additionally or alternatively, the template match method described above may be used to perform image alignment while focused on a planar target that is approximately orthogonal to a stereo optical axis of thestereoscopic visualization camera300. Moreover, the template match method may be used to align the left and right views in real-time whenever a “template match-able” scene is in view of both the left and right optical paths. In an example, a template image is copied from a subset of, for instance, the left view, centered upon or near the center of the view. Sampling from the center for an in-focus image ensures that a similar view of thetarget site700 will be present in the other view (in this example the right view). For out-of-focus images, this is not the case such that in the current embodiment this alignment method is performed only after a successful auto-focus operation. The selected template is then matched in the current view (or a copy thereof) of the other view (in this example the right view) and only a y-value is taken from the result. When the views are aligned vertically, the y-value of the template match is at or near zero pixels. A non-zero y-value indicates vertical misalignment between the two views and a correction using the same value of y is applied either to select the pixel readout set of the first view or a correction using the negated value of y is applied to the pixel readout set of the other view. Alternatively, the correction can be applied in other portions of the visualization pipeline, or split between pixel readout set(s) and said pipeline.
• In some examples, the operator may also manually align a right ZRP with an origin of thepixel grid1002. For instance, after determining a location of the right ZRP, the processor1562 (and/or the peripheralinput unit interface1574 or graphics processing unit1564) causes the right ZRP to be highlighted graphically on a right image displayed by thedisplay monitor512. Theprocessor1562 may also display a graphic indicative of the origin of thepixel grid1002. The operator uses controls305 and/or theuser input device1410 to steer the right ZRP to the origin. Theprocessor1562 uses instructions from the controls305 and/or theuser input device1410 to accordingly move one or more of theoptical elements1402. Theprocessor1562 may provide a stream of right images in real-time in addition to graphically displaying the current location of the right ZRP and origin to provide the operator updated feedback regarding positioning. The operator continues to provide input via controls305 and/or theuser input device1410 until the right ZRP is aligned. Upon receiving a confirmation instruction, theprocessor1562 stores a calibration point to a look-up-table reflective of positions of theoptical elements1402 at the set magnification level.
3. Comparison of Alignment Error
• The examplestereoscopic visualization camera300 produces less alignment error between right and left images compared to known digital surgical microscopes with stereoscopic cameras. The analysis discussed below compares spurious parallax generated by ZRP misalignment for a known digital surgical microscope with camera and the examplestereoscopic visualization camera300. Initially, both cameras are set at a first magnification level with a focal plane positioned on a first position of a patient's eye. Equation (3) below is used to determine working distance (“WD”) from each camera to the eye.
• 
  WD=(IPD/2)/tan(α)  Equation (3)
• In this equation, IPD corresponds to the interpupillary distance, which is approximately 23 mm. In addition, α is one-half of an angle between, for example, the rightoptical image sensor746 and the leftoptical image sensor748, which is 2.50° in this example. The convergence angle is two times this angle, which is 5°, in this example. The resulting working distance is 263.39 mm.
• The cameras are zoomed in to a second magnification level and triangulated on a second position of the patient's eye. In this example the second position is at the same physical distance from the camera as the first position, but presented at the second magnification level. The change in magnification generates spurious horizontal parallax due to misalignment of one or both of the ZRPs with respect to a center of a sensor pixel grid. For the known camera system, the spurious parallax is determined to be, for example, 3 arc-minutes, which corresponds to 0.05°. In Equation (3) above, the 0.05° value is added to α, which produces a working distance of 258.22 mm. The difference in working distance is 5.17 mm (263.39 mm−258.22 mm), which corresponds to the error of the known digital surgical microscope with camera attachment.
• In contrast, the examplestereoscopic visualization camera300 is capable of automatically aligning ZRPs to be within one pixel of a center of a pixel set or grid. If the angular field-of-view is 5° and recorded with a 4 k image sensor used in conjunction with a 4 k display monitor, the one pixel accuracy corresponds to 0.00125° (5°/4000) or 4.5 arc-seconds. Using Equation (3) above, the 0.00125° value is added to a, which produces a working distance of 263.25 mm. The difference in working distance for thestereoscopic visualization camera300 is 0.14 mm (263.39 mm−263.25 mm). When compared to the 5.17 mm error of the known digital surgical microscope, the examplestereoscopic visualization camera300 reduces alignment error by 97.5%.
• In some embodiments, thestereoscopic visualization camera300 may be more accurate at higher resolutions. In the example above, the resolution is about 4.5 arc-seconds for a 5° field-of-view. For an 8K ultra-high definition system (with 8000 pixels in each of 4000 rows) with a field-of-view of 2°, the resolution of thestereoscopic visualization camera300 is approximately 1 arc-second. This means that ZRP of the left and right views may be aligned to one pixel or 1 arc-second. This is significantly more precise than known digital microscope systems that have spurious parallax on the order of arc-minutes.
4. Reduction of Other Sources of Spurious Parallax
• The above-examples discuss how the examplestereoscopic visualization camera300 reduces spurious parallax as a result of misaligned ZRPs and/or left and right images themselves. Thestereoscopic visualization camera300 may also be configured to reduce other sources of spurious parallax. For example, thestereoscopic visualization camera300 may reduce spurious parallax due to motion by simultaneously clocking the right and leftoptical image sensors746 and748 to record images at substantially the same instant.
• The examplestereoscopic visualization camera300 may also reduce spurious parallax due to dissimilar magnification between the left and right optical paths. For example, thestereoscopic visualization camera300 may set the magnification level based on the left optical path. Thestereoscopic visualization camera300 may then make automatic adjustments so that the magnification of the right image matches the left. Theprocessor1562, for example, may use image data to calculate control parameters, for example by measuring a number of pixels between certain features common in the left and right images. Theprocessor1562 may then equalize the magnification levels of the left and right images by digital scaling, inserting interpolative pixels, and/or deleting extraneous pixels. Theexample processor1562 and/or thegraphics processing unit1564 may re-render the right image such that the magnification is matched to the left image. Additionally or alternatively, thestereoscopic visualization camera300 may include independent adjustment of the left and rightoptical elements1402. Theprocessor1562 may separately control the left and rightoptical elements1402 to achieve the same magnification. In some examples, theprocessor1562 may first set, for example, the left magnification level then separately adjust the rightoptical elements1402 to achieve the same magnification level.
• The examplestereoscopic visualization camera300 may further reduce spurious parallax due to dissimilar focus. In an example, theprocessor1562 may execute aprogram1560 that determines a best focus for each optical path for a given magnification and/or working distance. Theprocessor1562 first performs a focusing of theoptical elements1402 at a point of best resolution. Theprocessor1562 may then check the OOF condition at a suitable non-object-plane location and match the focus for the left and right images. Theprocessor1562 next re-checks the focus at best resolution and adjusts the focus iteratively until both left and rightoptical elements1402 focus equally well both on and away from an object plane.
• Theexample processor1562 may measure and verify optimal focus by monitoring a signal relating to the focus of one or both of the right and left images. For example, a “sharpness” signal is generated by thegraphics processing unit1564 for the left and right images simultaneously and/or in synchronization. The signal changes as focus changes and may be determined from an image-analysis program, an edge detection analysis program, a bandwidth of Fourier transforms of pattern intensity program, and/or a modulation transfer function (“MTF”) measurement program. Theprocessor1562 adjusts a focus of theoptical elements1402 while monitoring for a maximum signal indicative of a sharp image.
• To optimize the OOF condition, theprocessor1562 may monitor sharpness signals for both the left and right images. If the focus is moved off of the object plane and the signal related to, for example, the left image increases but the signal related to the right image decreases, theprocessor1562 is configured to determine theoptical elements1402 are moving out of focus. However, if the signals related to both the right and left images are relatively high and approximately equal, theprocessor1562 is configured to determine theoptical elements1402 are properly positioned for focusing.
5. Benefits of Low Spurious Parallax
• The examplestereoscopic visualization camera300 has a number of advantages over known digital surgical microscopes as a result of the low spurious parallax between right and left images. For example, almost perfectly aligned left and right images produce an almost perfect stereoscopic display for a surgeon, thereby reducing eye fatigue. This allows thestereoscopic visualization camera300 to be used as an extension of a surgeon's eyes rather than a cumbersome tool.
• In another example, precisely aligned left and right images allow accurate measurements of the surgical site to be digitally taken. For instance, a size of a patient's ocular lens capsule may be measured such that a properly-sized IOL can be determined and accurately implanted. In another instance, a motion of a moving blood vessel may be measured such that an infrared fluorescein overlay can be accurately placed in a fused image. Here, the actual motion velocity is generally not of interest to the surgeon but critical for the placement and real-time adjustment of the overlaid image. Properly matched scale, registration, and perspective of the overlaid images are all important to provide an accurately-fused combined live stereoscopic image and an alternate-mode image.
• In some examples, theprocessor1562 may enable an operator to draw measurement parameters on thedisplay monitor512. Theprocessor1562 receives the drawn coordinates on a screen and accordingly translates the coordinates to the stereoscopic image. Theprocessor1562 may determine measurement values by scaling the drawn ruler on the display monitor512 to a magnification level shown in the stereoscopic images. The measurements made by theprocessor1562 include point-to-point measurements of two or three locations displayed in the stereoscopic display, point-to-surface measurements, surface characterization measurements, volume determination measurements, velocity verification measurements, coordinate transformations, instrument and/or tissue tracking, etc.
VII. Example Robotics System for the Stereoscopic Visualization Camera
• As discussed in connection withFIGS. 5 and 6, an examplestereoscopic visualization camera300 may be connected to a mechanical orrobotic arm506 as part of a stereoscopic visualization platform or stereoscopicrobotic platform516. The examplerobotic arm506 is configured to enable an operator to position and/or orient thestereoscopic visualization camera300 above and/or next to a patient during one or more procedures. Accordingly, therobotic arm506 enables an operator to move thestereoscopic visualization camera300 to a desired field-of-view (“FOV”) of a target surgical site. Surgeons generally prefer cameras to be positioned and/or orientated in a FOV that is similar to their own FOV to enable easier visual orientation and correspondence between images displayed on a screen and the surgeon's FOV. The examplerobotic arm506 disclosed herein provides structural flexibility and assisted control to enable positioning to coincide or to be consistent with a surgeon's FOV without blocking the surgeon's own FOV.
• In contrast to the stereoscopicrobotic platform516 disclosed herein, known stereomicroscope holding devices include a simple mechanical arm that is manually moved by an operator. These devices include multiple rotational joints equipped with electromechanical brakes that allow manual repositioning. Further, to allow an operator to change a view easily and without interrupting a procedure, some known holding devices have motorized joints. The motorized joints have various levels of complexity ranging from, for example, simple X-Y positioning up to devices comprising multiple independent rotational joints that manipulate connected rigid arms. During most procedures, it is desirable to obtain views from various directions quickly and easily. However, known stereomicroscope holding devices suffer from one or more problems.
• Known stereomicroscope holding devices have limited position, direction, and/or orientation accuracy that is generally limited by the manual ability of the surgeon to manipulate the microscope to view desirable aspects of the image. Holding devices with multiple joints can be especially cumbersome to operate since device manipulation usually results in all the joints moving at the same time. Oftentimes, an operator is watching how an arm moves. After the arm is positioned in a desired location, the operator checks whether the imaging device's FOV is aligned in the desired location. Many times, even if the device is aligned properly, a focus of the device has to be adjusted. Further known stereomicroscope holding devices cannot provide consistent FOV or focal planes with respect to other objects in a targeted surgical site because the devices do not have arm position memories, or the memories are inaccurate as a patient is moved or shifted during a procedure.
• Known stereomicroscope holding devices generally have positioning systems in which control is independent of microscope parameters such as object plane focus distance, magnification and illumination. For these devices, coordination of positioning and, for example, zooming must be performed manually. In an example, an operator may reach a lens limit for focusing or changing a working distance. The operator has to manually change a position of the holding device, and then refocus the stereomicroscope.
• Known stereomicroscope holding devices are intended solely for observation of a surgical site. The known devices do not determine locations or distances from tissue within a FOV to another object outside the FOV. The known devices also do not provide comparisons of tissue with other objects within a live surgical site to form an alternative viewing modality, such as combining an MRI image with a live view. Instead, views from known devices are displayed separately and unaligned from other medical images or templates.
• Additionally, known stereomicroscope holding devices have parameters that may not be accurate since there is less emphasis on precision, other than for observation. The requirements in ISO Standard 10936-1:2000(E) “Optics and optical instruments—Operation microscopes—Part1: Requirements and test methods”, have largely been derived to achieve reasonable stereoscopic optical image quality using oculars by a normal human operator. The operator's brain combines the views into the mind's image to achieve stereopsis. The views are generally not combined or compared together otherwise. As long as the operator sees an acceptable image and does not suffer from deleterious effects like headaches their needs have been met. The same is true for stereomicroscope holding devices, where some instability, arm sag, and imprecise movement control are permitted. However, when high-resolution digital cameras are used with known holding devices, the structural inaccuracies are readily observable and may detract from their use, especially for microsurgical procedures.
• As mentioned above, known stereomicroscope holding devices may sag due to the weight of a camera. Generally, known robotic positioning systems are calibrated to determine compliance or inaccuracy only for the system itself. The stereomicroscope holding devices do not take into account the camera or any inaccuracy between a camera mount and the holding device. Sag is generally compensated by an operator manually positioning the camera while observing an image on a display. In systems that provide motorized motion, changes in sag occur, for example, when a center-of-gravity (“CG”) of the camera is re-positioned on an opposite side of a rotational axis of an arm joint, where restoring torque moment about the axis reverses direction. Subsequently any compliance or sag in the mechanism, which is compensated by an operator by adjusting the position, direction, and/or orientation of the camera, now adds to the position, direction, and/or orientation error. In some cases, for example when the camera is moved through a robotic singularity point, the moment reversal occurs quickly and the resulting camera image shifts in error quickly and excessively. Such error limits the ability of known stereomicroscope holding devices to, for example, accurately follow or track tissue or instruments in the site.
• Known stereomicroscope holding devices include features for spatially locating and tracking surgical instruments and providing their subsequent representative display on a monitor. However, these known systems require an additional stereoscopic locating camera or triangulation device, prominently located, as well as conspicuous fiducial devices on the instruments. The added devices add to complexity, cost and operational obtrusiveness.
• The example stereoscopicrobotic platform516 disclosed herein includes an examplestereoscopic visualization camera300 connected to a mechanical orrobotic arm506.FIGS. 5 and 6 illustrate an example of the stereoscopicrobotic platform516. Stereoscopic images recorded by thecamera300 are displayed via one or more display monitors512,514. Therobotic arm506 is mechanically connected to acart510, which may also support one or more of the display monitors512,514. The robotic arm may include, for example, an articulated robotic arm generally anthropomorphic in size, nature, function, and operation.
• FIG. 33 shows a side-view of themicrosurgical environment500 ofFIG. 5, according to an example embodiment of the present disclosure. In the illustrated example, the display monitor512 may be connected to thecart510 via amechanical arm3302 with one or more joints to enable flexible positioning. In some embodiments, themechanical arm3302 may be long enough to extend over a patient during surgery to provide relatively close viewing of a surgeon.
• FIG. 33 also illustrates a side-view of the stereoscopicrobotic platform516, including thestereoscopic visualization camera300 and therobotic arm506. Thecamera300 is mechanically coupled to therobotic arm506 via acoupling plate3304. In some embodiments, thecoupling plate3304 may include one or more joints that provide for further degrees of positioning and or orientation of thecamera300. In some embodiments, thecoupling plate3304 has to be manually moved or rotated by an operator. For example, thecoupling plate3304 may have a joint that enables thecamera300 to be positioned quickly between having an optical axis along a z-axis (i.e., pointing downward toward a patient) and an optical axis along an x-axis or y-axis (i.e., pointing sideward toward a patient).
• Theexample coupling plate3304 may include asensor3306 configured to detect forces and/or torques imparted by an operator for moving thecamera300. In some embodiments, an operator may position thecamera300 by gripping thecontrol arms304aand304b(shown inFIG. 3). After the operator has clutched thecontrol arms304aand304bwith their hands, the user may position and/or orient thecamera300 with assistance from the robotic arm306. Thesensor3306 detects a force vector or torque angle provided by the operator. Theexample platform516 disclosed herein uses the sensed force/torque to determine which joints of therobotic arm506 should be rotated (and how quickly the joints should be rotated) to provide assisted movement of thecamera300 that corresponds to the forces/torques provided by the operator. Thesensor3306 may be located at an interface between thecoupling plate3304 and thecamera300 for detecting the forces and/or torques imparted by an operator via the control arms304.
• In some embodiments, thesensor3306 may include, for example, a six-degrees-of-freedom haptic force-sensing module. In these embodiments, thesensor3306 may detect translational force or motion in the x-axis, y-axis, and z-axis. Thesensor3306 may also separately detect rotational force or motion around a yaw-axis, a pitch-axis, and a roll-axis. The decoupling of the translational force and the rotational force may enable the stereoscopicrobotic platform516 to more easily calculate direct and/or reverse kinematics for control of therobot arm506.
• Theexample sensor3306 may be configured to detect force since therobotic arm506 may not be movable by a user alone. Instead, thesensor3306 detects translational and rotational force applied by a user, which is used by the stereoscopicrobotic platform516 to determine which joints to rotate to provide assisted movement control of therobotic arm506. In other examples, therobotic arm506 may permit operator movement without assistance, or at least initial assistance. In these other examples, thesensor3306 detects motion imparted by the user, which is used by the stereoscopicrobotic platform516 to subsequently cause one or more joints to rotate, thereby providing assisted movement. The time between initial detection of motion or the force resulting in the motion, until the stereoscopicrobotic platform516 causes the joints to rotate may be less than 200 milliseconds (“ms”), 100 ms, 50 ms, or as few as 10 ms, where the user does not notice the initial time of unassisted movement of therobotic arm506.
• Theexample sensor3306 may output digital data that is indicative of the rotational force/motion and digital data that is indicative of the translational force/motion. In this example, the digital data may have 8, 16, 32, or 64 bit resolution for the detected force/motion in each axis. Alternatively, thesensor3306 may transmit an analog signal that is proportional to the sensed force and/or motion. Theexample sensor3306 may transmit the data at a periodic sampling rate of, for example, 1 ms, 5 ms, 10 ms, 20 ms, 50 ms,100, ms, etc. Alternatively, thesensor3306 may provide a near-continuous stream of force/motion data.
• In some embodiments, theexample sensor3306 may instead be located in one or more of thecontrol arms304aand304bor between thecontrol arms304aand304band thehousing302. In examples, where each of thecontrol arms304aand304bincludesensor3306, the example stereoscopicrobotic platform516 may receive two sets of translational and rotational force or motion. In these examples, the stereoscopicrobotic platform516 may average the values from thesensors3306.
• In the illustrated embodiments, a first end of therobotic arm506 is mounted to thecart510 while a second, opposite end of the robotic arm is mechanically connected to stereoscopic visualization camera300 (e.g., a robot end effector).FIG. 33 shows therobotic arm506 holding thestereoscopic visualization camera300 in an extended position, such as positioning thestereoscopic visualization camera300 above a surgical site while keeping the rest of theplatform516 out of the way of a surgeon. Thecart510 is configured to securely hold the stereoscopicrobotic platform516 and is weighted and balanced to prevent tipping under prescribed operating positions.
• The example stereoscopicrobotic platform516 is configured to provide the following benefits.
• • 1. Enhanced visualization. Communication between therobotic arm506 and thestereoscopic visualization camera300 enables theplatform516 to point and steer thecamera300 to quickly and more accurately visualize surgical sites. For example, therobotic arm506 can move thecamera300 along its optical axis to extend the range of focusing and zooming beyond that contained in just the camera. The relatively small size of theplatform516 provides for Heads-Up Surgery® in a wider variety of surgical procedures and orientations, thereby improving surgical efficiency and surgeon ergonomics.
  • 2. Enhanced dimensional performance. The examplestereoscopic visualization camera300, with its accurate measurement capability of all points within the stereoscopic image, is configured to communicate the measurement information to therobotic arm506. Therobotic arm506, in turn, comprises accurate position, direction, and/or orientation determination capability and is registered to thecamera300 such that the dimensions within and between images can be accurately transformed respective to a coordinate system common to the stereoscopicrobotic platform516 and an anatomy of a patient.
  • 3. The quality and accuracy of stereoscopic image data from thestereoscopic visualization camera300 enables it to be combined with image or diagnostic data from external sources of various modalities to construct fused images. Such fused images can be used by surgeons to perform procedures more accurately and efficiently and to achieve better patient outcomes.
  • 4. Thestereoscopic visualization camera300, therobotic arm506, and/or image and motion processors (e.g.,processor1408 ofFIG. 14) can be programmed for beneficial procedural applications. For example, a specific visualization site position, direction, and/or orientation can be saved, and then returned to later in the procedure. Precise motion paths can be programmed to, for example, follow a specific length or line of tissue. In other examples, pre-programmed waypoints can be set, thereby permitting an operator to change a position and/or orientation of therobotic arm506 based upon which step is being performed during a medical procedure.
  • 5. The stereoscopicrobotic platform516 provides for intrinsically guided surgery by use and analysis of accurate image position information. Such guidance can be communicated to other devices, such as another robotic system that performs at least portions of a surgical procedure. Components of the stereoscopicrobotic platform516 that share functionality with components of such other devices may be integrated together into a package to achieve efficiencies of performance, accuracy, and cost.
A. Robotic Arm Embodiment
• FIG. 34 illustrates an embodiment of the examplerobotic arm506, according to an example embodiment of the present disclosure. In some embodiments, therobotic arm506 is similar to or comprises model UR5 from Universal Robots S/A. The exterior surfaces of therobotic arm506 comprise aluminum and plastic materials, which are compatible for use in an operating room and easily cleaned.
• While therobotic arm506 is described herein as being electromechanical, in other examples, therobotic arm506 may be mechanical, hydraulic, or pneumatic. In some embodiments, therobotic arm506 may have mixed actuation mechanisms, for example, using a vacuum chuck with a control valve to hold and manipulate thecamera300. Further, while therobotic arm506 is described below as including a certain number of joints and links, it should be appreciated that therobotic arm506 may include any number of joints, any lengths of links, and/or comprise any types of joints, or sensors.
• As described herein, therobotic arm506 is situated and the joints are oriented to provide an unrestricted view of an operating field while providing a 3D stereoscopic display for an operator for any surgical procedure for a patient. Movement of therobotic arm506 in noncritical motions is provided to be fast enough for an operator to be convenient yet safe. Movement of therobotic arm506 is controlled during surgery to be meticulous and accurate. In addition, movement of the robotic arm is controlled to be smooth and predictable through the entire range of motion required for a surgical procedure. As described herein, movement of therobotic arm506 is controllable by remote control or via manual manipulation of the arm itself. In some embodiments, therobotic arm506 is configured to be positionable with minimal force (e.g., via an assisted guidance feature) with just the use of, for example, a single auricular finger.
• In some embodiments, therobotic arm506 may include mechanically or electronically locking brakes on the joints. The brakes may be engaged once the aim or “pose”, which is generally the location and direction, of thecamera300 after it is set by an operator. Therobotic arm506 may include a locking or unlocking switch or other input device to prevent undesired manual or accidental motion. When locked, the example robotic arm provides sufficient stability that enables thestereoscopic visualization camera300 to provide a stable, clear image. Therobotic arm506 may additionally or alternatively include one or more dampening devices to absorb or attenuate vibrations following movement of thestereoscopic visualization camera300 to a new pose. The dampening devices may include, for example, fluid-filled linear or rotational dampeners, rubber-based vibration isolation mounting dampeners, and/or tuned mass-spring dampeners. Alternatively, or in addition, thearm506 may include electromechanical dampening, for example, through the use of a proportional integral derivative (“PID”) servo system.
• The examplerobotic arm506 may be configured with a stowage position to which one or more links are returned for transportation and storage. A stowage position enables the robotic arm to be transported and stored in a concise footprint yet deployed with a long reach required in some surgical procedures. Cables, such as those routed for thestereoscopic visualization camera300, are provided along therobotic arm506 so as to avoid interference with a surgical procedure.
• In the illustrated embodiment ofFIG. 34, therobotic arm506 includes six joints, labeled R1, R2, R3, R4, R5, and R6. In other embodiments, therobotic arm506 may include fewer or additional joints. Additionally, in some embodiments, at least some of the joints R1 to R6 have rotational motion capabilities of +/−360°. The rotational motion may be provided by an electromechanical subsystem that includes, for each joint, an electric motor configured to drive a mechanical rotational joint through one or more anti-backlash joint gearboxes. Each of the joints R1 to R6 may include one or more rotational sensors to detect joint position. Further, each joint may include a slip clutch and/or an electromechanical brake.
• Each of the joints R1 to R6 may have an overall repeatability of motion (with thecamera300 attached) of approximately +/− 1/10 of a millimeter (“mm”). The joints may be have variable rotational speeds that can be controlled between 0.5° to 180° per second. Together, this translates to camera movement between 1 mm per second to 1 meter per second. In some embodiments, the stereoscopicrobotic platform516 may have speed governors for one or more of the joints R1 to R6 that are in place during surgical procedures. Each of the joints R1 to R6 may be electrically connected to a power source and/or command line in a controller of therobotic arm506. Wires for power and command signals may be routed internally within the joints and links. Further, one or more of the joints may include dampeners, such as o-rings for connection to links. The dampeners may, for example, reduce or absorb vibrations in therobotic arm506, vibrations from thecart510, and/or vibrations imparted via thestereoscopic visualization camera300.
• Joint R1 includes a base joint that is mechanically coupled to aflange3402, which is secured to astationary structure3404. Theflange3402 may include any type of mechanical connector. Thestationary structure3404 may include, for example, thecart510 ofFIG. 5, a wall, a ceiling, a table, etc. The joint R1 is configured to rotate around afirst axis3410, which may include the z-axis.
• Joint R1 is connected to joint R2 via alink3430. Theexample link3430 includes a cylinder or other tubular structure configured to provide structural support for the downstream sections of therobotic arm506. Thelink3430 is configured to provide a rotational secure connection with joint R2 to enable joint R2 to rotate while thelink3430 is held in place by its connection to the joint R1. Joint R2 may include, for example, a shoulder joint configured to rotate around anaxis3412. Theexample axis3412 is configured to be perpendicular (or substantially perpendicular) toaxis3410. Theaxis3412 is configured to be within an x-y plane given the rotation of the joint R1 around the z-axis.
• Joint R2 is mechanically coupled to joint R3 vialink3432. Thelink3432 is configured to have a greater length than thelink3430 and is configured to provide structural support for downstream portions of therobotic arm506. Joint R3 may include, for example, an elbow joint. Together with joint R2, joint R3 provides extensible positioning and/or orientating of therobotic arm506. The joint R3 is configured to rotate around anaxis3414, which is perpendicular or orthogonal to theaxis3410 and parallel to theaxis3412.
• Joint R3 is connected to joint R4 vialink3434, which provides structural support for downstream portions of therobotic arm506. The example joint R4 may be, for example, a first wrist joint configured to provide rotation aroundaxis3416, which may be orthogonal to theaxes3412 and3414. Joint R4 is mechanically connected to joint R5 vialink3436. Joint R5 may be a second wrist joint configured to provide rotation around anaxis3418, which is orthogonal toaxis3416. Joint R5 is mechanically connected to joint R6 vialink3438. Joint R6 may be a third wrist joint configured to rotate aroundaxis3420, which is orthogonal to theaxis3418. Together, the wrist joints R4 to R6 provide precise flexibility in positioning thestereoscopic visualization camera300 described herein.
• The examplerobotic arm506 includes aconnector3450. Theexample connector3450 is connected to joint R6 vialink3440. In some embodiments, theexample link3440 may include a sleeve that enables joint R6 to rotate theconnector3450. As discussed herein, theconnector3450 may be configured to mechanically couple to thecoupling plate3304 or thestereoscopic visualization camera300 directly when a coupling plate is not used. Theconnector3450 may include one or more screws to secure therobotic arm506 to thecoupling plate3304 and/or thestereoscopic visualization camera300.
• In some embodiments, therobotic arm506 of the illustrated example may have a maximum reach of 85 mm, in an orientation roughly similar to a human arm. Thearm506 may have a payload capacity of 5 kilograms. Further, thearm506 may be configured as a “collaborative” device to enable safe operation in the proximity of humans. For example, the maximum force that therobotic arm506 can apply to external surfaces is controlled. Should a portion of the robot arm unexpectedly contact another object, the collision is detected, and motion is instantly ceased. During an emergency stop situation where for example, power is lost the joints R1 to R6 can be back-driven or manually rotated such that an operator can grab part of the robotic system and swing it out of the way. For example, slip clutches within the joints limit the maximum torque the joint motor can apply rotationally to thearm506 during operation. When powered off, the slip clutches of the joints slip when manually manipulated to allow an operator to quickly move therobotic arm506 out of the way.
• FIGS. 35 to 40 illustrate example configurations of therobotic arm506 and thestereoscopic visualization camera300, according to example embodiments of the present disclosure.FIG. 35 shows a diagram of therobotic arm506 connected to thecart510 via theflange3402. In this example, thestereoscopic visualization camera300 is connected directly to the connector3540. In this embodiment, the connector3540 and/or thestereoscopic visualization camera300 may include thesensor3306 ofFIG. 33 for sensing translational and/or rotational force/motion imparted by an operator on thestereoscopic visualization camera300. If the connector3540 includes thesensor3306, the output force/motion data may be transmitted through therobotic arm506 to a controller. If, for example, thesensor3306 is located on thestereoscopic visualization camera300, the output data may be transmitted with control data to a separate controller. In some embodiments, a controller may be provided in thecart510 or separately at a server.
• FIG. 36 shows an embodiment where therobotic arm506 is mounted to aceiling plate3404 via theflange3402. The robotic arm may be suspended from the ceiling of an operating room to reduce floor space clutter. Therobotic arm506, including the joints, can be positioned above and traversed from the area where surgical activity is being performed, out of the way of the surgeon and operating room staff, yet still providing functional positioning and/or orientating of thecamera300 while providing a clear view of the display monitors512 and514.
• FIG. 37 shows an embodiment of thecoupling plate3304. In the illustrated example, afirst end3702 of thecoupling plate3304 is connected to theconnector3450 of therobotic arm506. Asecond end3704 of thecoupling plate3304 is connected to thestereoscopic visualization camera300. Theexample coupling plate3304 is configured to provide additional degrees of freedom for moving thestereoscopic visualization camera300. Thecoupling plate3304 also extends the maximum reach of therobotic arm506. Thecoupling plate3304 may have a length between 10 cm to 100 cm.
• Thecoupling plate3304 may include one or more joints. In the illustrated example, thecoupling plate3304 includes joints R7, R8, and R9. The example joints are mechanical joints that provide rotation around respective axes. The joints R7 to R9 may comprise rotatable latching mechanisms that are movable after an operator actuates a release button or lever. Each joint R7 to R9 may have its own release button, or a single button may release each of the joints R7 to R9.
• The joints R7 to R9 may be connected together via respective links. In addition, alink3718 is provided for connection to theconnector3450 of therobotic arm506. Joint R7 is configured to rotate aroundaxis3710, while joint R8 is configured to rotate aroundaxis3712, and joint R9 is configured to rotate aroundaxis3714. Theaxes3710 and3714 are parallel with each other and orthogonal to theaxis3712. Joints R7 and R9 may be configured to provide +/−360° rotation. In other examples, joints R7 and R9 may provide +/−90°, +/−180° rotation or +/−270° rotation around therespective axes3710 and3714. Joint R8 may provide +/−90° rotation around theaxis3712. In some examples, joint R8 may only be set at +90°, 0°, and −90°.
• In some embodiments, joints R7 to R9 may include motors that provide continuous movement. Joints R7 to R9 may also include control devices, such as switches or position sensors that communicate or provide data indicative or a rotational position. In this manner, the joints R7 to R9 may be similar to the joints R1 to R6 of therobotic arm506 and provide for assisted movement and positioning sensing for feedback control. Power and control for joints R7 to R9 may be provided via wires routed through therobotic arm506, power/wire connectors within theconnector3450, and/or wires external to therobotic arm506.
• FIG. 37 shows an example where thestereoscopic visualization camera300 is positioned in a horizontal orientation such that anoptical axis3720 is provided along a z-axis. The horizontal orientation may be used for imaging patients that are lying down. In contrast,FIG. 38 shows an embodiment where joint R8 is rotated by 90° to position thecamera300 in a vertical orientation such that theoptical axis3720 is provided along an x-axis or y-axis that is orthogonal to the x-axis. The vertical orientation may be used for imaging patients that are sitting. It should be appreciated that joint R8 enables thestereoscopic visualization camera300 to quickly be re-orientated between horizontal and vertical positions based on the procedure.
• In the illustrated examples ofFIGS. 36 and 37, theexample sensor3306 may be located at, for example, theconnector3450 of the robotic arm (with the connection of the coupling plate3304) and/or at thefirst end3702 of the coupling plate (at the connection with the connector3450). Alternatively or additionally, theexample sensor3306 may be located at, for example, thesecond end3704 of the coupling plate (at the connection with the camera300) and/or at thecamera300 at the connection with thesecond end3704 of thecoupling plate3304.
• FIGS. 39 and 40 show thestereoscopic visualization camera300 in the horizontal orientation and rotated +90° around theaxis3714 of joint R9.FIG. 40 shows an example of thestereoscopic visualization camera300 in the horizontal orientation and rotated −90° around theaxis3714 of joint R9.
• As illustrated inFIGS. 34 to 40, the examplerobotic arm506 is configured to provide support for thestereoscopic visualization camera300 and allow for precise positioning and/or orientating and aiming of the camera's optical axis. Since thestereoscopic visualization camera300 does not have oculars and does not need to be oriented for a surgeon's eyes, there are many desirable positions and/or orientations for imaging that may be achieved that were not previously practical. A surgeon can perform with the view most optimal for a procedure rather than that most optimal for his orientation to the oculars.
• The examplerobotic arm506, when used with thestereoscopic visualization camera300, enables a surgeon to see around corners and other locations that are not readily visible. Therobotic arm506 also enables patients to be placed into different positions including supine, prone, sitting, semi-sitting, etc. Accordingly, therobotic arm506 enables the patient to be placed in the best position for a specific procedure. The examplerobotic arm506, when used with thestereoscopic visualization camera300 can be installed for the least obtrusive position. Thearm506 andcamera300 accordingly provide a surgeon numerous possibilities for visual locations and orientations while being conveniently located and oriented out of the way.
• The arrangement of the links and joints of therobotic arm506 and/or thecoupling plate3304, along with the motorized six (or nine) degrees of freedom generally allow thecamera300 to be positioned as desired with the link and joint configuration not unique to the pose of the camera. As discussed in more detail below, the joints and links of thearm506 and/or theplate3304 may be manually repositioned and/or reoriented without changing the pose or FOV of thecamera300. This configuration allows, for example, an elbow joint to be moved out of an occluding line of sight without changing the view of the surgical site through thecamera300. Further, a control system can determine the location and pose of thecamera300 and calculate and display alternative positions and/or orientations of therobotic arm506 to, for example, avoid personnel or display occlusion. Use of the various positions and/or orientations of thecoupling plate3304 along with an ability of an image processor to flip, invert, or otherwise reorient the displayed image permit evenmore robot arm506 positions and/or orientations.
• Therobotic arm506 and/orcoupling plate3304 is/are generally situated, and the joints are positioned such that joint singularities are avoided in any general movement. The avoidance of joint singularities provides better robotic control of hysteresis and backlash. Further, the lengths and configurations of the links and joints of therobotic arm506 and/or thecoupling plate3304 provide for smooth movement along most any desirable motion paths. For example, repositioning and/or reorienting of therobotic arm506 enables it to change the direction of thecamera300 view of a target point within a surgical site without changing a focal point, thereby permitting a surgeon to view the same target point from different directions/orientations. In another example, therobotic arm506 is capable of changing a working distance to a target point without changing a focal point by translating thecamera300 along the line of sight towards or away from the target point. Numerous similar motion paths are attainable as desired using therobotic arm506 and/or thecoupling plate3304 with thestereoscopic visualization camera300 of the stereoscopicrobotic platform516.
B. Robotic Control Embodiment
• The examplerobotic arm506 and/or thecoupling plate3304 ofFIGS. 34 to 40 may be controlled by one or more controllers.FIG. 41 illustrates an embodiment of the stereoscopicrobotic platform516 ofFIGS. 3 to 40, according to an example embodiment of the present disclosure. The example stereoscopicrobotic platform516 includes thestereoscopic visualization camera300 and correspondingimage capture module1404 and motor andlighting module1406 described in connection withFIGS. 14 and 15.
• In the illustrated embodiment, the stereoscopicrobotic platform516 includes a server orprocessor4102 that is located remote from thestereoscopic visualization camera300. Theprocessor4102 may include, for example, a laptop computer, a workstation, a desktop computer, a tablet computer, a smartphone, etc. configured with one or more software programs defined by instructions stored in thememory1570 that, when executed by theprocessor4102, cause theprocessor4102 to perform the operations described here. Theexample processor4102 in this example is configured to include (or perform the operations described in connection with) theinformation processor module1408, theimage sensor controller1502, and/or the motor andlighting controller1520 ofFIGS. 14 to 16.
• In some examples, at least some of the operations of theimage sensor controller1502, and/or the motor andlighting controller1520 may be shared with theimage capture module1404 and motor andlighting module1406, respectively. For example, theprocessor4102 may generate commands for changing focus, magnification, and/or working distance, and via a first portion of the motor andlighting controller1520, and a second portion of the motor andlighting controller1520 within the motor andlighting module1406 controls thedrivers1534 to1552. Additionally or alternatively, a first portion of theinformation processor module1408 located operationally in theprocessor4102 is configured to receive individual left/right images and/or stereoscopic images from a second portion of theinformation processor module1408 in theimage capture module1404. The first portion of theinformation processor module1408 may be configured for processing the images for display on one or more display monitors512 and/or514 including, visually fusing images with graphical guidelines/text, image overlays from a Mill machine, X-ray, or other imaging device, and/or fluorescence images.
• Theprocessor4102 is electrically and/or communicatively coupled to theimage capture module1404 and motor andlighting module1406 of thestereoscopic visualization camera300 via awire harness4102. In some embodiments, theharness4102 may be external to therobotic arm506. In other embodiments, thewire harness4102 may be internal or routed through the robotic arm. In yet other embodiments, theimage capture module1404 and motor andlighting module1406 may communicate wirelessly with theprocessor4102 via Bluetooth®, for example.
• Theexample processor4102 is also electrically and/or communicatively coupled to thesensor3306 via thewire harness4102. Theprocessor4102 is configured to receive, for example, rotational and/or translational output data from thesensor3306. The data may include digital data and/or analog signals. In some embodiments, theprocessor4102 receives a near-continuous stream of output data from thesensor3306 indicative of detected force and/or motion. In other examples, theprocessor4102 receives output data at periodic sampled intervals. In yet other examples, theprocessor4102 periodically transmits a request message requesting the output data.
• In the illustrated example, theprocessor4102 is further communicatively coupled to at least one of adisplay monitor512,input devices1410a,1410b, and other devices/systems4104 (e.g., medical imaging devices such as an X-ray machine, a computed tomography (“CT”) machine, a magnetic resonance imaging (“MRI”) machine, a camera a workstation for storing images or surgical guidelines, etc.). Theinput device1410amay include a touch screen device and theinput device1410bmay include a foot switch. The touchscreen input device1410amay be integrated with thedisplay monitor512 and/or provided as a separate device on, for example, thecart510 ofFIG. 5. The example display monitor512 is configured to display one or more user interfaces that include a stereoscopic video (or separate two-dimensional left and right videos) of a target surgical site recorded by thestereoscopic visualization camera300.
• The touchscreen input device1410ais configured to provide one or more user interfaces for receiving user inputs related to the control of thestereoscopic visualization camera300, thecoupling plate3304, and/or therobotic arm506. Theinput device1410amay include one or more graphical control buttons, sliders, etc. that are configured to enable an operator to specify, set, or otherwise provide instructions for controlling a working distance, focus, magnification, source and level of illumination, filters, and/or digital zoom of thestereoscopic visualization camera300. Theinput device1410amay also include one or more control buttons to enable an operator to select surgical guidance graphics/text, a video and/or an image for fusing and/or otherwise superimposing on the displayed stereoscopic video displayed on thedisplay monitor512. Theinput device1410amay also include a user interface that is configured to enable an operator input or create a surgical procedure visualization template. Theinput device1410amay further include one or more control buttons for controlling therobotic arm506 and/or thecoupling plate3304, including options for controlling operational parameters such as speed, motion, deployment/stowing, calibration, target-lock, storing a view position, and/or changing or inputting a new orientation of thecamera300. The user interface controls for therobotic arm506 and/or thecoupling plate3304 may include controls for moving thecamera300, which are translated into commands for the individual joints R1 to R9. Additionally or alternatively, the user interface controls for therobotic arm506 and/or thecoupling plate3304 may include controls for moving each of joints R1 to R9 individually. Inputs received via theinput device1410aare transmitted to theprocessor4102 for processing.
• The example footswitch input device1410 may include, for example, a food pedal configured to receive inputs for controlling a position of thestereoscopic visualization camera300, thecoupling plate3304, and/or therobotic arm506. For example, the footplate input device1410bmay include controls for moving thecamera300 along the x-axis, the y-axis, and/or the z-axis. The footplate input device1410bmay also include controls for storing a position of thecamera300 and/or returning to a previously stored position. The footplate input device1410bmay further include controls for changing a focus, zoom, magnification, etc. of thecamera300.
• In other embodiments, the stereoscopicrobotic platform516 may include additional and/oralternative input devices1410, such as a joystick, mouse, or other similar 2D or 3D manual input device. Theinput devices1410 are configured to provide inputs similar to an X-Y panning device, with additional degrees of freedom resulting in flexibility of system motion. Input devices with 3D capabilities, such as a 3D mouse or six-degree of freedom controller are well suited for flexible and convenient input commands. A major benefit of these user control devices is that the surgical image can be easily viewed while the motion is occurring. Further, a surgeon can view what is happening around the entire surgical and nearby sites to avoid, for example, bumping thecamera300 into surgical staff and/or nearby equipment.
• Optionally, theinput device1410 may include a head, eye, or glasses-mounted tracking device, a voice recognition device, and/or a gesture input device. These types ofinput devices1410 facilitate “hands-free” operability such that an operator does not need to touch anything with their sterile gloves. A gesture-recognizing control may be used, where certain operation hand motions are recognized and translated into control signals for thecamera300, thecoupling plate3304, and/or therobotic arm506. A similar function is provided by a voice-recognition device, where a microphone senses a command from an operator, such as “move the camera left”, recognizes the speech as a command, and converts it into appropriate camera and/or robot control signals. Alternate embodiments include an eye tracking device that is configured to determine a position of an operator's eyes with respect to a 3D display, and can adjust the view depending on where in the displayed scene the operator is looking.
• Other embodiments include a device configured to track a position of an operator's head (via for example a trackable target or set of targets that are mounted on an operator's 3D glasses) in a frame of reference and a footswitch to activate “head tracking”. The example tracking input device is configured to store a starting position of an operator's head at activation time and then detects head position continually at some short time interval. The tracking input device in conjunction with theprocessor4102 may calculate a movement delta vector between a current position and the starting position and convert the vector into corresponding robotic arm or camera lens movements. For example, a trackinginput device1410 and theprocessor4102 may convert left/right head movements into robotic arm movements such that an image onscreen moves left/right. The trackinginput device1410 and theprocessor4102 may also convert up/down head movements into robotic arm or camera lens movements such that an image onscreen moves up/down, and may convert forward/back head movements into robotic arm or camera lens movements such that an image onscreen zooms in/out. Other movement conversions are possible, for example, by converting head rotation into a “lock-to-target” motion of therobotic arm506. As described here, lock-to-target is configured to maintain a focal point of therobotic platform516 on the same point in a scene or FOV to within some tolerance and pivot the robotic arm506 (and hence the view) in a direction which mimics the head movement of an operator.
• Prior to certain surgical procedures, a surgical plan is created that establishes desired paths for instruments and visualization. In some embodiments, theinput device1410 is configured to follow such a predetermined path with little further input from an operator. As such, the operator can continue operating while the view of the surgical site is automatically changing as pre-planned. In some embodiments, the surgical plan may include a set of pre-planned waypoints, corresponding to camera positions, magnification, focus, etc. An operator may actuate theinput device1410 to progress through the waypoints (causing theprocessor4102 to move therobotic arm506, thecoupling plate3304, and/or thecamera300 as planned) as the surgical procedure progresses.
• In the illustrated embodiment, theexample sensor3306 is an input device. Thesensor3306 is configured to detect an operator's movement or force on thestereoscopic visualization camera300 and convert the detected force/movement into rotational and/or translational data. Thesensor3306 may include a motion-anticipation input device, such as a six-degrees-of-freedom haptic force-sensing module or an opto-sensor (e.g., force/torque sensor), that enables therobotic arm506 to respond electromechanically to an operator's gentle push on thecamera300. The opto-sensor may include an electro-optical device configured to transform applied forces and/or torques into electrical signals, thereby enabling a desired force/torque input by an operator to be sensed and transformed into a motion request that is provided in the sensed linear and/or rotational direction(s). In other embodiments, other sensors types may be used for thesensor3306. For example, thesensor3306 may include a strain gauge or piezoelectric device that is configured to sense a haptic request from an operator.
• In an embodiment, a surgeon holds one or more of the control arms304 and actuates or pushes a release button (which may be located on one or both of the control arms304). Actuation of the release button causes thecamera300 to transmit a message to theprocessor4102 indicative that an operator desires to begin an “assisted-movement” mode. Theprocessor4102 configures therobotic arm506 and/or thecoupling plate3304 to enable the surgeon to gently steer thecamera300 in a desired direction. During this movement, theprocessor4102 causes therobotic arm506 and/or the coupling plate to move thecamera300 in a “power steering” manner, safely supporting its weight and automatically determining which joints should be activated and which should be braked in a coordinated manner to achieve the surgeon's desired movement.
• In the illustrated example, the stereoscopicrobotic platform516 ofFIG. 41 includes arobotic arm controller4106 that is configured to control therobotic arm506 and/or thecoupling plate3304. Therobotic arm controller4106 may include a processor, a server, a microcontroller, a workstation, etc. configured to convert one or more messages or instructions from theprocessor4102 into one or more messages and/or signals that cause any one of joints R1 to R9 to rotate. Therobotic arm controller4106 is also configured to receive and convert sensor information, such as joint position and/or speed from therobotic arm506 and/or thecoupling plate3304 into one or more messages for theprocessor4102.
• In some embodiments, therobotic arm controller4106 is configured as a stand-alone-module located between theprocessor4102 and therobotic arm506. In other embodiments, therobotic arm controller4106 may be included within therobotic arm506. In yet other embodiments, therobotic arm controller4106 may be included with theprocessor4102.
• The examplerobotic arm controller4106 includes one or more instructions stored in amemory4120 that are executable by arobotic processor4122. The instructions may be configured into one or more software programs, algorithms, and/or routines. Thememory4120 may include any type of volatile or non-volatile memory. The examplerobotic processor4122 is communicatively coupled to theprocessor4102 and is configured to receive one or more messages related to operation of therobotic arm506 and/or thecoupling plate3304. The examplerobotic processor4120 is also configured to transmit to theprocessor4102 one or more messages that are indicative of positions and/or speeds of joints R1 to R9. The one or more messages may also be indicative that a joint has reached a travel-stop or is being prevented from moving.
• Theexample processor4120 is configured to determine which joints R1 to R9 are powered in a coordinated manner such that a totality of all motions of all the joints results in the desired image motion at thecamera300. In a “move the camera left” example there may be complex motions of several joints which cause the camera's surgical image to appear to simply and smoothly translate to the left, from a relative viewpoint of a surgeon. It should be noted that in the “move the camera left” example, depending on how thecamera300 is connected to therobotic arm506 through thecoupling plate3304, the control signals to specific joints may be drastically different depending on the position/orientation.
• Thememory4120 may include one or more instructions that specify how joints R1 to R9 are moved based on a known position of the joints. Therobotic arm controller4106 is configured to execute the one or more instructions to determine how instructed camera movement is translated into joint movement. In an example, therobotic arm controller4106 may receive messages from theprocessor4102 indicative that thestereoscopic visualization camera300 is to move downward along a z-axis and move sideward in an x-y plane. In other words, theprocessor4102 transmits indicative of inputs received via theinput devices1410 regarding desired movement of thecamera300. The examplerobotic arm controller4106 is configured to translate the vectors of movement in 3-dimensional coordinates into joint position movement information that achieves the desired position/orientation. Therobotic arm controller4106 may determine or take into account the current location of the links and joints of therobotic arm506 and/or the coupling plate3304 (and/or a position/orientation of the camera300) in conjunction with the desired movement to determine a movement delta vector. In addition, therobotic arm controller4106 may perform one or more checks to ensure the desired movement does not cause thecamera300 to enter into or progress close to a restricted area, as specified by one or more three-dimensional boundaries that are defined in the same coordinate system as thearm506 andcoupling plate3304. Areas close to a boundary may specify a reduced scale factor that is applied by therobotic arm controller4106 when movement signals are sent to the joints, which causes the joints to move slower as therobotic arm506 approaches a boundary, and not move any further past a boundary.
• After the boundary checks are performed, therobotic arm controller4106 uses the movement delta and the current position/orientation of each of joints R1 to R9 to determine an optimal or near optimal movement sequence for rotating one or more of the joints to cause therobotic arm506 to move thecamera300 into the specified location. Therobotic arm controller4106 may use, for example, an optimization routine that determines a minimal amount of joint movement needed to satisfy the movement delta vector. After the amount of joint movement is determined, the examplerobotic arm controller4106 is configured to send one or more messages (indicative of an amount of rotation and speed of rotation, taking into account any scale factors) to amotor controller4124. Therobotic arm controller4106 may transmit a sequence of messages to cause therobotic arm506 and/orcoupling plate3304 to move in a defined or coordinated sequence. The sequence of messages may also cause a change in joint speed as, for example, therobotic arm506 approaches a virtual or physical boundary.
• Theexample motor controller4124 is configured to translate or covert the received messages into analog signals, such as pulse-width modulated (“PWM”) signals that cause one or more of joints R1 to R9 to rotate. Themotor controller4124 may, for example, select the input line to the appropriate joint motor, where a pulse duration is used for controlling a duration of time that the motor rotates and a frequency, duty cycle, and/or amplitude of the pulse is used to control rotation speed. Themotor controller4124 may also provide power for the joint motors and corresponding joint sensors.
• In some embodiments, therobotic arm controller4106 in combination with themotor controller4124 is configured to receive or read joint sensor position information and determine, through kinematics, the location and orientation of the robotic joints andcamera300. Each joint R1 to R9 may include at least one sensor that detects and transmits data indicative of joint position, joint rotational speed, and/or joint rotational direction. In some embodiments, the sensors transmit only position information, and speed/direction are determined by therobotic arm controller4106 based on differences in the position information over time. Therobotic arm controller4106 may transmit the sensor data to theprocessor4102 for determining movement information.
• Therobotic arm controller4106 receives movement instructions from theprocessor4102 and determines, through Jacobian, forward, and/or inverse kinematics, which motors and joints should be activated, how fast and how far, and in what direction. Therobotic arm controller4106 then sends the appropriate command signals to motor power amplifiers in themotor controller4124 to drive the joint motors in therobotic arm506.
• The examplerobotic arm506 receives appropriate motor power signals and moves accordingly. Sensors and brakes in thearm506 react to the various operations and feedback information from therobotic arm controller4106. In some embodiments, therobotic arm506 is mechanically and communicatively connected to thecoupling plate3304, which transmits coupler status and orientation information to therobotic arm controller4106.
• In some embodiments, the examplerobotic arm506 ofFIG. 41 includes acoupler controller4130. Theexample coupler controller4130 is configured to bypass therobotic processor4106 and relay control information between theprocessor4102 and thecoupling plate3304. Thecoupler controller4130 may receive messages from theprocessor4102 and correspondingly cause joints R7 to R9 rotate on thecoupling plate3304. Thecoupler controller4130 may also receive sensor information regarding joint position and/or speed and transmit one or more messages to theprocessor4102 indicative of the joint position and/or speed. In these embodiments, theprocessor4102 may transmit messages for controlling therobotic arm506 and separate messages for thecoupling plate3304.
• In some embodiments, therobotic arm controller4106 is configured to determine how joints R7 to R9 are to move. However, if thecoupling plate3304 is not communicatively coupled directly to therobotic arm506, therobotic processor4106 may transmit the movement signals to thecoupler controller4130 via theprocessor4102. In instances where at least some operators of therobotic processor4106 are located with theprocessor4102, thecoupler controller4130 receives movement commands or signals from theprocessor4102 in conjunction with therobotic arm506 receiving movement commands or signals from theprocessor4102.
• In the illustrated embodiment ofFIG. 41, the examplestereoscopic visualization camera300, theprocessor4102, thecoupling plate3304, therobotic arm506, therobotic arm controller4106, and/or theinput devices1410 receive power via aninput power module4140. Theexample module4140 includes a power supply (such as power from a wall outlet) and/or an isolation transformer to prevent powerline anomalies from disrupting system performance. In some instances, the power supply can include a battery power supply.
• Thestereoscopic visualization platform516 may also include anemergency stop switch4142 that is configured to immediately cut off power. Theswitch4142 may only cutoff power to therobotic arm506 and/or thecoupling plate3304. Theprocessor4106 may detect activation of theemergency stop switch4142 and cause joint brakes to engage to prevent therobotic arm506 from falling. In some instances, therobotic arm506 is configured to activate the joint brakes after detecting a loss of power. In some embodiments, joints R1 to R6 of therobotic arm506 are configured to slip if a force above a threshold is applied, thereby enabling an operator to quickly move the arm out of the way in an emergency, with or without power.
• In some embodiments, theexample processor4102 is configured to display one or more graphical representations of therobotic arm506, thecoupling plate3304, and/or thestereoscopic visualization camera300. Theprocessor4102 may cause the graphical representation to be displayed in one or more user interfaces that provide control for therobotic arm506, thecoupling plate3304, and/or thecamera300. Theprocessor4102 may position and orient the graphical representation to reflect the current position of therobotic arm506, thecoupling plate3304, and/or the camera. Theprocessor4102 uses, for example, feedback messages from therobotic arm controller4106 to determine which joints in the graphical representation are to be rotated, thereby changing the orientation and/or position of the display device. In some instances, theprocessor4102 is configured to receive user input via the graphical representation by, for example, an operator moving the links, joints, orcamera300 in the graphical representation to a desired position. In the case of movement of thestereoscopic visualization camera300, theprocessor4102 may transmit the new coordinates corresponding to where the camera was moved. In the case of moved joints or links, theprocessor4102 may transmit to therobotic arm controller4106 messages indicative of joint rotation and/or positions of links.
• In some embodiments, theprocessor4102 operates in connection with therobotic arm controller4106 to adjust one or more lenses of the camera based on or in cooperation with movement of therobotic arm506 and/or thecoupling plate3304. For example, if therobotic arm506 is moved toward a surgical site, theprocessor4102 operates in connection with therobotic arm controller4106 to change a working distance or focal point by moving one or more of the lenses of thestereoscopic visualization camera300 to maintain focus. Theprocessor4102 operates in connection with therobotic arm controller4106 to determine, for example, that movement of therobotic arm506 causes a working distance to decrease. TheEPU processor4102 operates in connection with therobotic arm controller4106 to determine a new position for the lenses based on the new working distance set by moving therobotic arm506. This may include moving one or more lenses for adjusting focus. In some embodiments, theprocessor4102 may instruct thecamera300 to operate a calibration routine for the new position of therobotic arm506 to eliminate, for example, spurious parallax.
• In some instances, an operator may be changing positions of one or more lenses of thestereoscopic visualization camera300 and reach a lens travel limit. The position of the lenses is sent from thecamera300 to theprocessor4102, which to determine that a limit has been reached. After detecting that a limit has been reached, theprocessor4102 may cause therobotic arm506 to move (via the controller4106) based on input from the operator, thereby extending their command from lens movement to arm movement to reach a desired magnification or target area. As such, theprocessor4102 operating in connection with therobotic arm controller4106 enables an operator to use only one user interface rather than changing between an interface for the robotic arm and the camera. It should be appreciated that theprocessor4102 and/or thecontroller4106 may check desired movement against any predetermined movement limits to ensure the movement will not cause thecamera300 orrobotic arm506 to enter into restricted patient or operator space. If a limit violation is detected, theprocessor4102 in connection with therobotic arm controller4106 may display an alert to the operator (via a user interface displayed on thetouchscreen input device1410aand/or the display monitor512) indicative of the limit to indicate a reason therobotic arm506 was stopped.
C. Robotic Arm and Stereoscopic Camera Calibration Embodiment
• As discussed above, the examplestereoscopic visualization camera300 is configured to provide high-resolution stereoscopic video images of a target surgical site at different magnifications. As part of thestereoscopic visualization platform516, thestereoscopic visualization camera300 operates in connection with therobotic arm506 and/or thecoupling plate3304 for precise and clear changes to image focus, working distance, magnification, etc. To accomplish the image acquisition flexibility, thestereoscopic visualization platform516 is configured to operate one or more calibration, initialization, and/or reset routines. In some embodiments, thestereoscopic visualization camera300, therobotic arm506, thecoupling plate3304, or more generally, thestereoscopic visualization platform516 is calibrated during manufacture and/or after installation. Calibration of thecamera300 with therobotic arm506 provides positioning information of thecamera300 relative to therobotic arm506 and operator space. After power-up of thestereoscopic visualization platform516, in some embodiments, thecamera300 and/or therobotic arm506 is configured to perform further calibration/initialization to measure and verify a location and orientation of thecamera300 at that time.
• Theexample processor4102 is configured to store results from the calibration (e.g., calibration data), in for example, thememory1570 and/or thememory4120 ofFIG. 41. The calibration results may be stored to calibration registers and/or lookup tables (“LUTs”) in thememories1570 and/or4120. The stored calibration data relates or maps optical, functional, and/or performance characteristics to attributes of thecamera300, therobotic arm506, and/or thecoupling plate3304 that are adjustable, measurable, and/or verifiable by an operator or by theprocessor4102. For example, a working distance actuator motor encoder position for the main objective assembly702 (ofFIG. 7) is mapped in a LUT to a working distance. In another example a zoom lens axial position along a linear encoder for thezoom lens assembly716 is mapped in a LUT to the magnification level. For each of these examples, theexample processor4102 is configured to determine the proper level of an encoder characteristic, adjust, and verify that the characteristic provides the specified or desired working distance and/or magnification. In some embodiments, LUTs may be compound, where multiple performance characteristics are mapped tomultiple platform516 attributes for overall control of all relevant aspects of thecamera300, therobotic arm506, and/or thecoupling plate3304.
• The combination of arobotic arm506 and the examplestereoscopic visualization camera300 provides highly accurate position, direction, and/or orientation information of the target view with respect to a frame of reference of therobotic arm506. The following sections describe how thestereoscopic visualization camera300 is calibrated to define a visual tip. After a visual tip is determined, thestereoscopic visualization camera300 is registered to a frame of reference of therobotic arm506 and/or thecoupling plate3306. Accordingly, after calibration and registration, a stereoscopic view of a surgical site is unified with the integrated control of thestereoscopic visualization camera300 combined with the position, direction, and orientation control of therobotic arm506 and/orcoupling plate3304.
• In some embodiments, theexample processor4102 ofFIG. 41 is configured to integrate a registration ofstereoscopic visualization camera300, including its visual tip, precisely with a position, direction, and/or orientation calibration of therobotic arm506 to define a unified position, direction, and/or orientation awareness of acquired stereoscopic images and all points therewithin, with respect to a prescribed coordinate frame. Theexample processor4102 is configured to use intrinsic visual imaging data from thestereoscopic visualization camera300 to coordinate or direct the physical positioning and/or orientating of therobotic arm506 to provide visualization, as desired by an operator. In addition, such direction and coordination provided by theprocessor4102 is provided to maintain preferred characteristics of the visualization such as focus, working distance, pre-defined positioning, orientating, etc.
• In some embodiments, calibration of thestereoscopic visualization camera300, therobotic arm506, and/or thecoupling plate3304 generally includes (i) determining and/or measuring inaccuracies of functional parameters of thestereoscopic visualization platform516 that affect stereoscopic images; (ii) calibrating or adjusting, thestereoscopic visualization platform516 to minimize the inaccuracies in the stereoscopic images at or below a desired level; (iii) verifying that the adjustments have been made within a desired level of calibration accuracy through simultaneous comparisons of the dual channels of the stereoscopic images to each other or calibration templates; and (iv) using thestereoscopic visualization platform516 in the performance of its tasks, where a level of the accuracy of the calibration is detectable and maintained.
• In an alternative embodiment, therobotic arm506 is provided with one or more fixed calibration fiducials that are used to precisely calibrate a physical relationship of the joint and links of therobotic arm506 to one another as well as to calibrate a relationship of the visual tip of thecamera300 to therobotic arm506 and/or an initial pose configuration. The robotic platform fixed calibration fiducials can be used to register or integrate therobotic arm506 with an external environment, such as an operating room theater or with a patient or target space within an external environment. The fixed calibration fiducials can either include a dedicated attachment to an external portion of a body of therobotic arm506 or a combination of known external features of therobotic arm506, such as mounting points, joints, corners, or the like.
1. Calibration of the Stereoscopic Visualization Camera Embodiment
• To match a stereoscopic view of a surgical site, theexample processor4102 and/or thestereoscopic visualization camera300 is configured to perform one or more calibration routines. The example routines may be specified by one or more instructions stored in thememory1570, that when executed by theprocessor4102, cause theprocessor4102 to determine lens position corresponding to certain working distances, magnifications (e.g., zoom level), and focus levels. The instructions may also cause theprocessor4102 to operate one or more routines for determining a center of projection, stereo optical axis, and/or a ZRP for thestereoscopic visualization camera300 at different working distances and/or magnifications. Calibration enables, for example, theprocessor4102 to retain focus on a target surgical site when magnification and/or working distance is changed.
• FIG. 42 illustrates anexample procedure4200 or routine for calibrating thestereoscopic visualization camera300, according to an example embodiment of the present disclosure. Although theprocedure4200 is described with reference to the flow diagram illustrated inFIG. 42, it should be appreciated that many other methods of performing the steps associated with theprocedure4200 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure4200 may be performed among multiple devices including, for example theoptical elements1402, theimage capture module1404, the motor andlighting module1406, and/or theinformation processor module1408 of the examplestereoscopic visualization camera300. For example, theprocedure4200 may be performed by one of theprograms1560 of theinformation processor module1408.
• Theexample procedure4200 begins when thestereoscopic visualization camera300 is powered or otherwise initialized (block4202). Thecamera300 may be mounted to therobotic arm506. Alternatively, theprocedure4200 can be performed when thestereoscopic visualization camera300 is connected to a fixed mount. Theexample procedure4200 next performs ZRP alignment, as discussed above in connection withFIGS. 25 and 26 (block4204). Theexample processor4102 may automatically align the ZRPs, as discussed above, and/or operate in connection with an operator to provide alignment of the left and right optical paths on theimage sensors746,748. In some examples, theprocessor4102 and/or an operator may cause small movements or flexing of a flexure (e.g., theflexure1300 ofFIG. 13) via a motor with sufficient accuracy to make very small adjustments to a tilt of a lens component to move a ZRP into alignment with a pixel grid origin. During semi-manual alignment, theprocessor4102 may cause left and right images from theimage sensors746 and748 to be overlaid on thedisplay monitor512. An operator may use theinput device1410 to adjust the images, causing pixel sets of thesensors746 and748 to be accordingly moved until the ZRPs are properly aligned.
• During alignment, the ZRPs are set to be aligned at an image center to avoid spurious parallax. Alignment to within about a single pixel on a display is possible. The degree of alignment from the left and right views to an image center is visible in the overlaid images, including during zooming operations. In an example of a 8° FOV, the use of a4K image sensor746,748 and a corresponding 4K display resolution of the display monitor512 (comprising about 4000 pixels by about 2000 rows) produces a system resolution of 8°/4000 pixels=7 arc-seconds. However, ZRP alignment can be performed at most any magnification, where the resolution (being the same number of pixels (e.g. 4000)) is divided by a reduced (or increased) angular FOV. For example, an exemplary embodiment of thecamera300 at a high magnification produces an angular FOV of about 2°. An 8K UHD display monitor512 andsensors746 and748 have about 8000 pixels in about 4000 rows. The resolution of this system is 2°/8000 pixels=1 arc-seconds. This is about an order of magnitude, or more, better than known systems in the art, in which the accuracy of assembled, individually-measured components with tolerances that have resolutions measured in arc-minutes. As images sensors and display monitors become higher in density with generally smaller pixels in the same physical sensor or display space, the accuracy of thestereoscopic visualization camera300 adjustability scales with the smaller pixel size. The enhanced high accuracy alignment of thestereoscopic visualization camera300 provides for better, more accurate digital effects.
• The alignment of the ZRPs is complete when the ZRPs of the left and right images remain at an image center within a desired tolerance range and the images of the target surgical site remain accurate when cycled from low magnification to high magnification. After the ZRPs are aligned throughout the magnification capabilities of thestereoscopic visualization camera300, the pixel set locations and/or lens locations for each of the magnification levels are stored to, for example, aLUT4203 or other data structure. In other examples, theprocessor4102 writes, to calibration registers, the pixel set locations and/or lens locations for each of the magnification levels.
• After the ZRPs are aligned, theexample processor4102 is configured to calibrate for working distance and/or magnification (e.g., zoom) (block4206). As discussed above in connection with the working distance and zoom examples ofFIG. 15, precise knowledge of working distance is important in thecamera300 so that therobotic arm506 may precisely position the camera relative to desired coordinates. In some instances, an accurate fiducial is used, along with mechanical dimensions of therobotic arm506, to transform object plane data from an image into a coordinate system respective of thestereoscopic visualization platform516, referred to herein as robot space.
• Theexample calibration procedure4200 is performed to map the working distance of the optical system of thestereoscopic visualization camera300, where the working distance may be calculated or measured in millimeters from a front face of a common mode objective (“CMO”) lens assembly (e.g., the front working distance mainobjective lens408 ofFIGS. 4 and 7) to an object plane. The working distance is mapped to a known measurable parameter, such as for example, a focus motor position, measured in counts of a motor shaft encoding device from a known “home” location such as a physical stop or limit switch trigger position.
• The calibration atblock4206 is performed by theprocessor4102 sequentially moving the object plane in discrete steps along the optical axis and re-focusing the image while recording the encoder counts and the working distance, as discussed in more detail in conjunction withFIG. 43. Theprocessor4102 measures the working distance externally from the front face of the CMO. The mapping of the encoder counts and the working distance is stored to theLUT4203, or a different LUT and/or calibration registers. This calibration enables theprocessor4102 to output an encoder count position to the motor controller, given a desired working distance. Exemplary embodiments of thestereoscopic visualization camera300 use high-count-per-revolution shaft encoding devices, where resolution of the working distance is on the order of 1 micron per each encoder count. Alternative embodiments may include different encoder resolution to provide higher or lower resolution of working distance, as desired.
• FIG. 43 shows an embodiment of the examplestereoscopic visualization camera300 moving an object plane in discrete steps, according to an example embodiment of the present disclosure. The examplestereoscopic visualization camera300 includes the mainobjective assembly702 ofFIG. 7 (e.g., a single CMO), which is configured to provide left and right views of a target surgical site. In the illustrated example, the mainobjective assembly702 is shown as an achromatic refractive assembly with the stationary front workingdistance lens408 within ahousing4302 and the movable rear workingdistance lens740, which is movable along the z-axis (or other optical axis). Movement of therear working distance704 changes the distance to the frontworking distance lens408. The spacing between thelenses408 and704 determines the overall frontfocal length4304 of the mainobjective assembly702, and accordingly the location of a front focal plane (or simply “focus plane”)4306. The frontfocal plane4306 is located at a distance equal to thefocal length4304 from aprincipal plane4308 of the mainobjective assembly702. It may be difficult to gauge the location of theprincipal plane4308, so a distance from the bottom surface ofhousing4302 to the front focal plane is defined as theworking distance4310. Theworking distance4310 accordingly accurately sets a plane of the target site or scene that is in focus.
• Imaging an object at the frontfocal plane4306 develops a conjugate image located at infinity from a back or rear of the mainobjective assembly702. Two parallel optical paths comprising optics andsensors714,716,718,744R, and744L of thecamera300, transversely separated by an interpupillary distance (“IPD”)4312, generate left and right views along respective left4320 and right4322 optical axes in slightly different directions from anoptical axis4324 of the mainobjective assembly702. The two optical paths are adjusted such that their respective external converging left and right axes are set to coincide at the center of the FOV of animage4330. Thispoint4330 is referred to herein as the “tip” of thestereoscopic visualization camera300 at the frontfocal plane4306.
• Adjustment of a position of the rearworking distance lens740 causes a change in the frontfocal length4304 mainobjective assembly702. As illustrated, a change in the position of the rearworking distance lens740 creates anew working distance4310′ that is located at the position of a new frontfocal plane4306′. The movement of the rearworking distance lens740 also causes a realignment of left4320′ and right4322′ optical axes, resulting in a relocatedtip4330′ of thecamera300. Visualization of an object with thecamera300 above or below thefocus plane4306 diminishes a focus of the object.
• In a manner similar to that for working distance calibration, a similar LUT, or additional columns in aworking distance LUT4203, can be constructed by theprocessor4102 varying the magnification while measuring an image height of an object of known size. Magnification can be quantified by determining the counts of the motor shaft encoding device from a known “home” location such as a physical stop or limit switch trigger position. Theprocessor4102 can measure image height relatively, for example in a number of sensor pixels at each magnification position. Magnification can be characterized by, for example dividing the height in pixels by the height in millimeters.
• Returning toFIG. 42, after the working distance and magnification of thestereoscopic visualization camera300 are calibrated, theexample processor4102 is configured to determine a center of projection (block4208). The center of projection (e.g., COP) may be determined using one or more routines that model thestereoscopic visualization camera300, as discussed above in connection withFIG. 15. To match the left and right stereoscopic view of a surgical site, it is often desirable to model thephysical camera300 using a mathematical model implemented in software, firmware, hardware, and/or GPU code for theprocessor4102. A perspective of a 3D computer model, such as the Mill image of a brain tumor, can often be rendered and viewed from user-adjustable directions and distances (e.g. as if the images are captured by a synthesized stereoscopic camera). The adjustability of the model may be used by theprocessor4102 to match a perspective of a live surgical image, which must therefore be known.
• Exemplary embodiments of thestereoscopic visualization camera300 and/orprocessor4102 are configured to accurately measure and calculate camera model parameters for each value of magnification and working distance. These values are controlled by separate optics contained within thestereoscopic visualization camera300. The dual optics are aligned such that the parallax at the center of an image between the left and right channels/views is approximately zero at thefocal plane4330. Additionally, thestereoscopic visualization camera300 is parfocal across the magnification range, and par central across magnification and working distance ranges because the ZRPs of each left and right channel have been aligned to the centers of their respective pixel grids (described above in block4202). In other words, changing only the magnification keeps the image in focus in both channels, and trained on the same center point. Similarly, changing only a working distance should cause no vertical parallax in the image, only increased horizontal parallax between the left and right views, if the target andstereoscopic visualization camera300 remain stationary.
• FIG. 44 illustrates agraph4400 illustrative of a routine executable by theprocessor4102 for determining a COP of thestereoscopic visualization camera300, according to an example embodiment of the present disclosure. In the illustrated example, a COP of a pinhole or modeledcamera300 is along anoptical axis4402 at the plane of the pinhole (O). To determine the COP for the camera model, a virtual pinhole camera model is used, where theprocessor4102 is configured to determine anactual focus distance4404 from the COP to an object plane. During the calibration routine, theprocessor4102 keeps the magnification of thecamera300 fixed while measurements are recorded of animage height4406, for example in the number of pixels at a plane of theoptical image sensor744, with an object ofheight4408 at three different distances along the optical axis4402: at the object plane, and at a distance “d” less than the object plane distance, and at a distance “d” greater than the object plane distance. Theprocessor4102 uses routines that include algebra based on similar triangles at the two most extreme positions to determine thefocus distance4404 to aCOP4410. Theprocessor4102 may determine focus distance at alternative magnifications based on the ratio of the alternative magnification to the magnification used for the calibration.
• Returning toFIG. 42, theexample processor4102 is configured to determine COPs for varying working distances and magnifications. Theprocessor4102 relates motor shaft encoder counts for the lenses to the COP for the varying working distances and magnifications in theLUT4203, a different LUT, or one or more calibration registers. In some embodiments, theprocessor4102 may only store a relation of a COP for one magnification and/or working distance and calculate the other magnifications and/or working distances using the one known COP relation.
• After calibrating for a COP, theexample processor4102 is configured to calibrate stereoscopic left and right optical axes and an interpupillary distance (“IPD”) between the axes of the stereoscopic visualization camera300 (block4210). To characterize the optics of thestereoscopic visualization camera300, the IPD between the left and right channels/views should be known. In embodiments, the IPD may be designed into the mechanical components holding the sensors and optics shown inFIG. 7. IPD is thus set mechanically. However, the actual optical axis may differ from the mechanical axis of the optical elements and their mounts. Other embodiments enable the IPD to be varied within thestereoscopic visualization camera300.
• In some applications, it is desirable to precisely know the direction of the stereoscopic optical axis with respect to a fiducial or mechanical axis on a frame of thestereoscopic visualization camera300. This enables, for example, theprocessor4102 to aim thestereoscopic visualization camera300 precisely through mechanical means. The aiming can be characterized by a geometrically-defined view vector, looking out coincidentally with the stereoscopic optical axis, with respect to a frame of reference of thestereoscopic visualization camera300. In addition, clocking of the left and right channels for theoptical sensor744 is included in a view vector, comprising thestereoscopic visualization camera300 orientation or pose.
• FIG. 45 shows a plan view of an optical schematic that is illustrative of how the IPD of thestereoscopic visualization camera300 may be measured and calibrated, according to an example embodiment of the present disclosure. In the illustrated example, anoptical axis4502 is perfectly aligned with amechanical axis4504. Theright image sensor746 and the left image sensor748 (as approximated by one or more camera models) are spaced by anIPD4506. Thesensors746 and748 are aligned and focused on an object4508 (in a target surgical site). Theobject4508 is placed at afocus distance4510 from thesensors746 and748 such that parallax at the plane of the object is theoretically zero, as depicted in the display of the left or right view of object atfocus plane4512. In this exemplary example, for clarity theobject4508 is a disc, the front view of which is shown asitem4514.
• FIG. 45 also illustrates another example where theobject4508 is displaced along the mechanical axis a distance “d” and is shown asitem4508′. The displacement of theobject4508 generates parallax, which appears in the displays of aleft view4520 as P_Land aright view4522 as P_R. In this example, the mechanical and optical axes are coincident and the parallax magnitudes are equal. The parallax can be measured, for example by counting a number of pixels of disparity between the left andright views4520 and4522 and multiplying by a magnification factor pixels/mm that was determined in the COP calibration step. Theprocessor4102 may calculate the IPD using triangulation. The accuracy of the measurements of the displacement distance d and the parallax of each view contribute to a precise knowledge of the IPD of thestereoscopic visualization camera300.
• FIG. 46 shows a plan view of an optical schematic that is illustrative of how the optical axis of thestereoscopic visualization camera300 can be measured and calibrated, according to an example embodiment of the present disclosure. In this example, theoptical axis4502 is misaligned from themechanical axis4504 by an angle (a), shown as4602. Theright image sensor746 and the left image sensor748 (as approximated by one or more camera models) are aligned and focused on an object4508 (in a target surgical site) that is placed at a focus distance such that parallax at the plane of theobject4508 is theoretically zero, as depicted in the display of the left or right view ofobject4508 atfocus plane4604.
• FIG. 46 also illustrated another example where theobject4508 is displaced along the mechanical axis the distance “d” and shown asobject4508′. The displacement of theobject4508 generates parallax, which appears in the displays of theleft view4610 as P_Landright view4612 as P_R. In this example where themechanical axis4504 and theoptical axis4502 are not coincident, the parallax magnitudes are not equal. Theexample processor4102 is configured to calculate the IPD as well as the misalignment angle α (e.g., the stereoscopic optical axis) via triangulation. The accuracy of the measurements of the displacement distance d and the parallax of each view enable theprocessor4102 to accurately determine the IPD and the optical axis of thestereoscopic visualization camera300.
• A similar procedure can be employed to measure, for example, misalignment of the mechanical and optical axes in the vertical plane. The combination of misalignment in, for example, the horizontal plane or vertical plane, can be combined such that a view vector can be accurately deduced with respect to the mechanical axis. In some embodiments, the IPD and optical axis parameters may be measured at varying levels of working distance and/or magnification. The relations between IPD, optical axis, working distance, and/or magnification may be stored by theprocessor4102 to theLUT4203, another LUT, and/or calibration registers.
• Returning toFIG. 42, after the optical axis and/or IPD of the examplestereoscopic visualization camera300 is calibrated, theexample processor4102 is configured to complete the calibration process to enable thecamera300 to be connected to the robotic arm506 (block4212). Theprocedure4200 may then end. In some embodiments, at least portions of theexample procedure4200 are repeated if thecamera300 is reinitialized and/or if any of the calibration cannot be verified or validated.
• It should be appreciated that the above steps of theprocedure4200 can be performed manually or semi-manually in some embodiments. In other embodiments, the above steps may be performed automatically and continuously by theprocessor4200. In some embodiments, measuring can be made through image recognition of a suitable target or any target with a sufficient number of objects comprising sufficient contrast to enable identification in both left and right views. In addition, theprocessor4102 may determine or calculate parallax measurements for assessing accurate relative positions of the optical elements of thestereoscopic visualization camera300. Theprocessor4102 may perform optical measurement on a real-time basis.
• In some embodiments, the use of automated, iterative techniques to perform these or equivalent methods of calibration and measurement can increase the accuracy and reduce the time and/or effort required to calibrate and measure. For example, the working distance (and hence the displacement d) is accurately known by the quantity of encoder counts and theLUT4203, as described previously. The magnification and its, for example, pixels/mm conversion factor is also accurately known by the quantity of encoder counts and theLUT4203, as described previously. Counting of pixels in the images for disparity or object size determination can be accurately performed manually or automated, for example, as described previously using template matching. The measurement and storage of these values can be combined such that the stereoscopic camera model parameters and view vector can be accurately deduced in near real-time by theexample processor4102.
• FIG. 47 illustrates a diagram of a calibratedstereoscopic visualization camera300 in which the optical parameters are fully characterized. In the illustrated embodiment, the left and right optical axes are shown leading to imaginary left and rightimage sensor positions4700, as determined via a camera model.FIG. 47 also shows the central stereoscopic optical axis orview vector4702. The imaginary left and right view components of the camera models are positioned at a focal distance Z. In addition, the left and right view components of the camera models are spaced apart by the measured, effective IPD. In the illustrated example, an object at the focal plane is viewed with similar stereoscopic perspective by the imaginary left and right view components as recorded by theimage sensors746 and748 within thestereoscopic visualization camera300.
2. Calibration of the Stereoscopic Visualization Enables Fusion with Additional Images
• Theexample processor4102 is configured to use the calibration parameters/information for not only providing high-resolution clear images, but also to align live stereoscopic images with one or more images/models received from theexternal devices4104. The mapping of the calibration data related to camera model parameters in theLUT4203 and/or calibration registers enables theprocessor4102 to create a mathematical model of thestereoscopic visualization camera300 that is implemented in software, firmware, hardware and/or computer code. In an example, theprocessor4102 is configured to receive, determine, or access camera model parameters using, for example, theprocedure4200 discussed in conjunction withFIG. 42. If a calibration has already been performed, theprocessor4102 accesses the camera model parameters from one ormore memories1570 and/or4120. Theprocessor4102 also receives, from thedevice4104, an alternative modality of the image data, such as pre-surgical images, MM images, a 3D model of the surgical site from MM or CT data, X-ray images, and/or surgical guides/templates. Theprocessor4102 is configured to render a synthesized stereoscopic image of the alternative modality data using the camera model parameters. Theexample processor4102 is also configured to provide the synthesized stereoscopic image for display via themonitor512. In some examples, theprocessor4102 is configured to fuse the synthesized stereoscopic image with the current stereoscopic visualization, where desirable aspects of each modality are visible and/or overlaid in identical perspective as if acquired by a single visualization device.
• In some embodiments, the parameters illustrated inFIG. 47 are used by theprocessor4102 to match a synthesized stereoscopic image of alternative modality, for example MRI image data, to the stereoscopic perspective of thestereoscopic visualization camera300. Thus, theexample processor4102 uses the stored optical calibration parameters for stereoscopic image synthesis. In an example, theprocessor4102 uses the optical calibration parameters to fuse live stereoscopic images with a three-dimensional model of a brain tumor that was imaged pre-operatively using an MRI device. Theexample processor4102 uses the optical calibration parameters to select the corresponding location, size, and or orientation of the three-dimensional model of the brain tumor that matches the stereoscopic images. In other words, theprocessor4102 selects a portion of the three-dimensional model that corresponds to the view recorded by thestereoscopic visualization camera300. Theprocessor4102 may also change which portion of the model is displayed based on detecting how the working distance, magnification, and/or orientation of thecamera300 changes.
• Theprocessor4102 may cause a graphical representation of the model to be overlaid of the stereoscopic images and/or cause the graphical representation of the model to appear visually fused with the stereoscopic images. The image processing performed by theprocessor4102 may include smoothing boundaries between the graphical representation of the model and the live stereoscopic view. The image processing may also include causing at least a portion of the graphical representation of the model to have an increased transparency to enable the underlying live stereoscopic view to also be visible to a surgeon.
• In some examples, theprocessor4102 is configured to generate and/or render a depth map for every pixel in a stereoscopic image. Theprocessor4102 may use the calibration parameters to determine, for example, tissue depth in an image. Theprocessor4102 may use the depth information for image recognition to note tissue of interest and/or identify instrument location to avoid inadvertent contact when thecamera300 is mated with therobotic arm506. The depth information may be output by theprocessor4102 to, for example, robotic suturing devices, diagnostic equipment, procedure monitoring and recording systems, etc. to conduct a coordinated and at least semi-automated surgical procedure.
3. Calibration of the Robotic Arm Embodiment
• After thestereoscopic visualization camera300 is calibrated, as discussed above, it may be connected to therobotic arm506 and/or thecoupling plate3304. As described below, precise knowledge of the working distance with respect to focal distance Z, provided by the stored calibration parameters, is used by theexample processor4102 and/or therobotic processor4122 for determining a position and/or orientation for thestereoscopic visualization camera300. The combination of thestereoscopic visualization camera300 with the robotic arm is configured to provide seamless transitions of various working distances while holding a focus or view of a target surgical site.
• The calibration procedure for therobotic arm506, described below, may be executed regardless of a robotic arm type. For example, the calibration procedure may be performed for an articulated robotic system that includes mechanical links connected to each other via rotary joints, numbering from simple one or two links and joints, to joint structures comprising six or more joints. The calibration procedure may also be performed for a Cartesian robotic system that comprises a gantry with linear joints, which uses a coordinate system with X, Y and Z directions. A final joint of a Cartesian robotic system may comprise a wrist type swiveling joint. The calibration procedure may further be performed for a cylindrical robotic system that comprises a rotary joint at its base and one or more additional rotary and/or linear joints to form a cylindrical workspace. Moreover, the calibration procedure may be performed for a polar robotic system that comprises an arm connected to a base via a joint that may operate in more than one rotational axis and further comprises one or more linear or wrist joints. The calibration procedure may additionally be performed for a Selective Compliance Assembly Robot Arm (“SCARA”) system that comprises a selectively compliant arm operated in a primarily cylindrical fashion, which is used for assembly applications.
• FIG. 48 illustrates anexample procedure4800 or routine for calibrating therobotic arm506, according to an example embodiment of the present disclosure. Although theprocedure4800 is described with reference to the flow diagram illustrated inFIG. 48, it should be appreciated that many other methods of performing the steps associated with theprocedure4800 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure4800 may be performed among multiple devices including, for example theoptical elements1402, theimage capture module1404, the motor andlighting module1406, theinformation processor module1408 of the examplestereoscopic visualization camera300 ofFIG. 14 and/or joints R1 to R9 androbotic arm controller4106 ofFIG. 41. For example, theprocedure4800 may be performed by a program stored in thememory4120 of therobotic arm controller4106.
• In some embodiments, thecoupling plate3304 is connected to the robotic arm506 (block4802). If acoupling plate3304 is not used, thestereoscopic visualization camera300 is connected directly to the connection orcoupling interface3450 of therobotic arm506. If thecoupling plate3304 is used, thestereoscopic visualization camera300 is connected to the coupling plate (block4804). As discussed above,first end3702 of thecoupling plate3304 is connected to therobotic arm506 and thesecond end3704 of thecoupling plate3304 is connected to thestereoscopic visualization camera300.
• After the examplestereoscopic visualization camera300 is connected to therobotic arm506, theexample processor4102 and/or therobotic arm controller4106 are configured to calibrate the camera and its view vector into a coordinate system originated around thestationary base3404 of the robotic arm506 (block4806). The coordinate system is referred to herein as “robot space” or “robotic space”. During this calibration step, known movements to therobotic arm506 are used by theprocessor4102 and/or therobotic arm controller4106 to determine an orientation and a location of a view vector and object plane of thecamera300 during visualization of a target surgical site.
• In some embodiments, the mechanical features of thecamera300, thecoupling plate3304, and therobotic arm506 exist such that, when mechanically connected together, the relationship between thecamera300, thecoupling plate3304, and therobotic arm506 is uniquely determined and known. In these embodiments, theprocessor4102 and/or therobotic arm controller4106 determine the position, direction, and/or orientation of the view vector from the known mechanical geometry of thecamera300, thecoupling plate3304, and therobotic arm506.
• In other embodiments where the mechanical features do not exist, theexample processor4102 and/or therobotic arm controller4106 are configured to perform a routine to accurately determine a spatial relationship between thecamera300 and therobotic arm506 in robot space. Theprocessor4102 and/or therobotic arm controller4106 move thestereoscopic visualization camera300 to a start position, which may include a stow position, a re-orientation position, or a surgical position. Thestereoscopic visualization camera300 then moves the camera from the start position to a position that approximately visualizes a calibration target located on thestationary base3404 of therobotic arm506. The calibration target may be located, for example, at a convenient area of thecart510 in a position within the motion sphere of therobotic arm506. Some examples of the calibration target include, for example, small spheres or other uniquely recognizable objects that can be located relative to each other (in two-dimensional or stereoscopic images) in a unique, known orientation. The coordinates of the spheres are fixed and known with respect to thecart510 andstationary base3404, and are hence known in robot space. Theprocessor4102 and/or therobotic arm controller4106 are configured to store the coordinates to, for example, thememory4120.
• During the calibration, theprocessor4102 and/or therobotic arm controller4106 receiveview vector data4807 regarding working distance, magnification, stereoscopic optical axis, and/or IPD. Thestereoscopic visualization camera300 is set to visualize the spheres at the calibration target simultaneously and determine their position through the use of parallax in the stereoscopic image. Theprocessor4102 and/or therobotic arm controller4106 records the positions of the spheres in an initial coordinate system, for example, X, Y, and Z with respect to a fiducial in the camera300 (i.e. “camera space). The X,Y,Z position may correspond to an origin location, and be defined in a file or LUT as being the origin or having other known coordinate values. Theprocessor4102 and/or therobotic arm controller4106 also use output data from joint sensors to determine position and orientation of the joints and links in therobotic arm506. Theprocessor4102 and/or therobotic arm controller4106 also receive position information to determine a position and orientation of thecoupling device3304. Together, the position and orientation of therobotic arm506 and thecoupling device3304 enable theprocessor4102 and/or therobotic arm controller4106 to determine a pose of thecamera300. Theprocessor4102 and/or therobotic arm controller4106 are configured to perform a coordinate transformation between the camera space and robot space based on the positions of the spheres of the calibration target as recorded by the camera, and as the positions of therobotic arm506 and/orcoupling plate3304. Theprocessor4102 and/or therobotic arm controller4106 may store the coordinate transformation to theLUT4203, a different LUT for therobotic arm506, and/or one or more calibration registers.
• In some embodiments, thecamera300 is moved to record images of multiple calibration targets located either on acart510, a ceiling, a wall, and/or within a surgical area. Each of the calibration targets may have a unique orientation that enables it physical X, Y, Z location to be identified. Theprocessor4102 and/or therobotic arm controller4106 perform additional coordinate transformations for each of the calibration targets and store the transformations to one or more LUTs and/or registers.
• In other embodiments, theprocessor4102 and/or therobotic arm controller4106 may use alternative methods to calibrate thecamera300 to robot space. In this context, “calibration” is taken to mean “registration”, where theprocessor4102 and/or therobotic arm controller4106 are configured to calculate registration over a wide space in which the registration may vary. For example, a system can be used where a separate stereoscopic camera is used to observe and locate calibration targets on thecart510 as well as similar calibration targets which are installed on thecamera300 and/or on a patient or surgical bed. Theprocessor4102 and/or therobotic arm controller4106 are configured to model and track thecamera300, which is modeled and tracked as a surgical instrument with a view vector and working distance. The view vector and working distance define parameters for accurately visualizing a target surgical site. In these other embodiments, the other camera determines and reports location and orientation information for the coordinate frame of each such instrument in a reference frame, such as thestereoscopic camera300. Then, using linear algebra, the poses and/or locations of instruments relative to each other are calculated by theprocessor4102 and/or therobotic arm controller4106, thereby resulting in a calibration of thecamera300 to the robot space.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are also configured to calibrate for thecoupling plate3304. In some instances, thecoupling plate3304 includes one or more switches that activate depending on a position of joints R7 to R9. The known position of the switches is used by theprocessor4102 and/or therobotic arm controller4106 as part of the coordinate transformation. Additionally or alternatively, thecoupling plate3304 is calibrated by causing therobotic arm506 to move while images from thecamera300 are monitored to determine orientation. In an example where thecoupling plate3304 is orientated as shown inFIG. 37, therobotic arm506 is commanded to move in a direction relative to an assumed orientation (for example, moving thecamera300 along the z-axis). If the assumed orientation is as shown inFIG. 37, wherein thecamera300 is aimed downward, a downward movement of therobotic arm506 should cause an object in the image to get larger as thecamera300 gets closer. If, for example, the object in the image, instead moves sideways or up/down, then theprocessor4102 and/or therobotic arm controller4106 are configured to detect the motion and determine that the assumed orientation is incorrect. Theprocessor4102 and/or therobotic arm controller4106 may generate an error and prompt an operator for the correct orientation and/or determine the correct orientation based on the detected movement in the images. The change in the image from movement of thecamera300 is deciphered automatically through use of, for example, image matching template algorithms, as described previously. In some embodiments, the use of matching template algorithms by theprocessor4102 and/or therobotic arm controller4106 determines joint orientation at thecoupling plate3304, which is stored to a LUT for calibration.
• FIG. 49 shows a diagram that is illustrative of how thestereoscopic visualization camera300 and/or therobotic arm506 are calibrated to robot space, according to an example embodiment of the present disclosure. In the illustrated embodiment, each of joints R1 to R9 and corresponding links are modeled based on rotational capabilities and/or lengths. Thememory4120 may store the mathematical parameters associated with the model. Further, theprocessor4102 and/or therobotic arm controller4106 may use the mathematical model to determine, for example, a current position of therobotic arm506 and/orcamera300, which may be used for calculating how joints are to be rotated based on intended movement provided by an operator.
• In the illustrated example, joint R1 is provided at a coordinate position of (0,0,0). The lengths between the joints R1 to R9 correspond to a length of the links. In the illustrated example, thestereoscopic visualization camera300 is modeled as a robot end effector that is connected to nine couplers. The three-dimensional space shown inFIG. 49 is modeled using a sequence of ten homogeneous transformations, which may include matrix multiplications. The first six frames or joints R1 to R6 represent the forward kinematics of therobotic arm506, and may be calculated using the Denavit-Hartenberg parameters of a robotic arm. The next three frames or joints R7 to R9 represent the transform from the tool-tip of therobotic arm506 to a tip of thecoupling plate3304. The last frame R10 represents the transform from the tool-tip of thecoupling plate3304 to the control point of thestereoscopic visualization camera300.
• Frame or joint R7 represents the pitch joint of thecoupling plate3304, which, can change between 0° and 90°. Frame or joint R8 represents the yaw joint of thecoupling plate3304, and can change between −90°, 0°, and 90°, depending on the yaw configuration. Joints R7 to R9 of the coupling plate may include a voltage source and a potentiometer. Theconnector3450 and/or thecoupler controller4130 of therobotic arm506 may include an I/O tool-tip connector that is configured to receive a voltage output from the potentiometer. Theprocessor4102 and/or therobotic arm controller4106 are configured to receive the output voltage and correspondingly determine pitch and yaw angles of thecoupling plate3304. Theprocessor4102 and/or therobotic arm controller4106 combines the pitch and yaw information of the coupling plate with sensor output data from joints R1 to R6 of therobotic arm506 to calculate position of the frames R1 to R10 to determine the three-dimensional position of therobotic arm506, thecoupling plate3304, and/or thecamera300.
• The control point representsframe10 at the very end of the kinematic chain, and is fully programmable in terms of position based on which feature is selected. For example, if an operator selects an assisted drive feature, theprocessor4102 and/or therobotic arm controller4106 are configured to set the control point representative of thecamera300 to be inside of the camera along an axis of rotation of the control arms304. In another example, if an operator selects a lock-to-target feature, theprocessor4102 and/or therobotic arm controller4106 are configured to set the control point of thecamera300 to an origin of an optical axis view vector.
• Returning toFIG. 48, the after calibrating thecamera300 to robot space, theprocessor4102 and/or therobotic arm controller4106 are configured to calibrate the robot space to patient space (block4808). Calibration of patient space is need to enable thestereoscopic visualization platform516 to make accurate visualizations of a patient, where the orientation between robot system and patient is needed. In some embodiments this orientation is fixed. In other embodiments the orientation, if varying, is sensed and known. In some embodiments a patient is placed in an operating room bed and registered to the bed using one ormore fiducials4809. For example, if a patient is undergoing brain surgery, they are secured to a bed and an external frame is fixed to their skull. The frame is observable by thestereoscopic visualization camera300 and may comprisefiducials4809 in an arrangement such as that of the calibration target where two or more non-collinear objects of known locations are visible simultaneously, such that the position and orientation of the frame, and hence the patient's skull, is capable of being determined. Other embodiments may usefiducials4809 that are implanted into a patient and are visible in MM or similar images.Such fiducials4809 can be used to accurately track and register a patient's skull as well as the MM image to a coordinate system representative of patient space. Further, other embodiments may use image recognition of features native to the patient themselves. For example, facial or similar recognition using biometric data, in-situ x-ray, or similar alternative modality imaging can be used to precisely locate a position and orientation of the patient. In another example, a model of a surface of a patient's face can be determined using one or more depth map calculations as described above, and surface matching functions performed by theprocessor4102 and/or therobotic arm controller4106.
• In an embodiment, a position and orientation of an operating room bed with respect to robot space is fixed and determined. Some embodiments comprise a rigid frame which mechanically registers the bed to, for example, fittings on thecart510 in a known position and orientation. Alternatively, the bed can be fixed with respect to therobotic arm506 and fiducials can be used to determine position and orientation. For example, therobotic cart510 and bed can be anchored to the floor and fixed for the duration of the procedure.
• After visualization of the patient'sfiducials4809 by thecamera300, their position and orientation in robot space can be deciphered and stored by theprocessor4102 and/or therobotic arm controller4106, where coordinate system transformations from robot space to patient space are enabled. It is noted that coordinate system transformations from one space to another are generally selectable and reversible. For example, it may be more efficient to transform desired camera motions or poses into robot space to enable theprocessor4102 and/or therobotic arm controller4106 to determine discrete joint motion and orientation. Alternatively, it may be easier and more efficient to present information to a surgeon on the display monitor512 in patient space. Location of points and vectors can be transformed by theprocessor4102 and/or therobotic arm controller4106 to be respective of most any coordinate system, for example, a cart origin, a patient reference frame, GPS, and/or other coordinate systems as desired.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to use automated, iterative techniques to perform these or equivalent methods of robot/patient space calibration and measurement to increase accuracy and reduce calibration time. In exemplary embodiments, the displacement and orientation of thestereoscopic visualization camera300 with respect to fiducials is accurately known by theprocessor4102 and/or therobotic arm controller4106. Motion of therobotic arm506 can be accurately performed, and the subsequent images of fiducials can be accurately analyzed. The visualization and knowledge of the calibration parameters can be combined by theprocessor4102 and/or therobotic arm controller4106 such that measurement, and hence calibration can be accurately performed in an automated manner. This is important, for example, to maintain accurate calibrations from one surgical procedure and one patient to the next.
• In some examples, theprocessor4102 and/or therobotic arm controller4106 are configured to determine boundaries of therobotic arm506 and/orcamera300 relative to the patient space and/or robot space. The boundaries represent virtual limits that are implemented in the software to prevent therobotic arm506 and/or thecamera300 from contacting or escaping defined areas or spaces. In some examples, the limits are defined in one or more LUTs or registers stored in thememory4120 as scale factors that are applied to joint movement signals by theprocessor4102 and/or therobotic arm controller4106. The magnitude of the scale factor is decreased to zero as the limit to each individual boundary is approached. For example, the joint rotation amount and speed may be determined based on operator input. However, theprocessor4102 and/or therobotic arm controller4106 scales the joint rotation speed by the scale factor before sending the signal(s) to the appropriate joint(s). In addition, theprocessor4102 and/or therobotic arm controller4106 may maintain the rotation amount such that the joint moves the desired amount, but at a reduced speed, until the joint reaches the boundary. It should be appreciated that a joint in a rotation area where a scale factor is applied may not have a scale factor applied if the desired movement is away from the boundary. Thus, theprocessor4102 and/or therobotic arm controller4106 may apply a scale factor to certain joints while applying a scale factor of ‘1’ to other joints based on a current position and estimated desired movement from an operator.
• The scale factors are strictly between zero and one, which enables chaining them together and enables the software to support an infinite number of possible boundaries. The scale factors may be lineally decreased as a boundary is approached, which causes a gradually slowing of the rotation of joints R1 to R9 as therobotic arm506 approaches a boundary. In other examples, the scale factors may decrease exponentially as a boundary is approached.
• Generally, operators typically focus their attention on the surgical field or the stereoscopic image on thedisplay monitor512. As such, the operators are typically unaware of the position of the individual links of therobotic arm506 and/or thecoupling plate3304. Therefore, it is not always intuitive when therobot arm506 is about to reach a limit or impact another part of therobot arm506. The joint limits may therefore always be active and prevent any part of therobot arm506 from hitting itself or putting the joints in a singular configuration, such as elbow lock. Theexample processor4102 and/or therobotic arm controller4106 are configured to determine the scale factor based on a current position of therobotic arm506. Theprocessor4102 and/or therobotic arm controller4106 may also take into account intended movement instructions provided by an operator to determine which scale factor is to be applied. Based on current and/or anticipated movement, theprocessor4102 and/or therobotic arm controller4106 calculates the scale factors based on distances in joint angle space using, for example, one or more LUTs. The joint angle spacing may define certain combinations of joint angles that are known to cause joint lock or cause therobotic arm506 to hit itself. As such, the joint angle spacing determination is based on determining and comparing current (and/or anticipated) movements of joints relative to each other.
• In addition to the boundaries for therobotic arm506, thememory4120 may store boundaries that relate to Cartesian limits that prevent therobotic arm506 from hitting thecart510, the robotic arm from hitting thedisplay monitor512, and/or thecamera300 from hitting therobotic arm506. Theprocessor4102 and/or therobotic arm controller4106 may use, for example, the coordinate system discussed in conjunction withFIG. 49 for determining and/or applying the Cartesian limits. In some examples, the limits may be relative or anchored to a certain link. As such, when the link is moved in the 3D space, the boundary around it moves accordingly. In other examples, the limits are static and fixed to certain coordinate planes or lines within the 3D space shown inFIG. 49. Theprocessor4102 and/or therobotic arm controller4106 may apply the limits by calculating or determining scale factors in Cartesian space and applying the forward kinematic transform.
• Theexample processor4102 and/or therobotic arm controller4106 may also determine a patient boundary, which defines a virtual place that no point of therobotic arm506 and/orcamera300 can violate. Patient boundaries may be determined by calculating scale factors in Cartesian space for a distance of each positional joint on therobotic arm506 and/or thecoupling plate3304 to a location of a boundary plane. The boundary plane, as shown inorientation5002 ofFIG. 50 is implemented as an X,Y plane located at some vertical Z location for non-pitched configurations. For pitched configurations, such as patient semi-sitting shown inorientation5004 ofFIG. 50, the boundary plane is set as a Y,Z plane located at either positive or negative X values depending on the direction thecamera300 faces.
• The example boundaries discussed above may be stored to thememory4120 as default boundaries and/or determined by theprocessor4102 and/or therobotic arm controller4106 prior to a surgical procedure. In some embodiments, certain boundaries may be accessed or determined based on an inputted type of surgical procedure to be performed. For example, patient boundaries may be determined by thecamera300 imaging the patient and determining patient depth using calibration information/parameters. Theprocessor4102 and/or therobotic arm controller4106 may then create and apply a boundary to a specified location above or next to the patient. Similar boundaries may be created after detection of monitors, surgical staff, or surgical instruments.
• For instance, boundaries can be determined around the use of a specific surgical tool such that tools of larger size or tools that pose certain risks if contacted. Theexample processor4102 and/or therobotic arm controller4106 may receive an input of the tool type and/or detect the tool in the stereoscopic images using image analysis. In other examples, theprocessor4102 and/or therobotic arm controller4106 calculate depth information in relation to a surgical instrument to determine its size, orientation, and/or position. Theexample processor4102 and/or therobotic arm controller4106 translate the image of the surgical instrument into the coordinate system, such as the one discussed in connection withFIG. 49. Theprocessor4102 and/or therobotic arm controller4106 also apply scale factors having a value less than ‘1’ to areas that correspond to a location of the surgical instrument, thereby preventing therobotic arm506 and/or thecamera300 from inadvertently contacting the surgical tool. In some instances, theprocessor4102 and/or therobotic arm controller4106 may track a movement of the surgical tool during a procedure and change the boundary accordingly.
• FIG. 51 illustrates an example of how the rotational joint speed of therobotic arm506 and/or thecoupling plate3304 is scaled based on distance to a boundary, according to an example embodiment of the present disclosure.Graph5102 shows a velocity of rotation for joint R1 andgraph5104 shows a shoulder angle (e.g., rotation position)5110 in relation to afirst zone5112 that corresponds to an area close to a boundary where a scale factor is reduced from a value of ‘1’ and a second zone5114 that corresponds to the boundary where the scale factor is reduced to a value of ‘0’.
• FIG. 51 shows that as therobotic arm506, and in particular joint R1 causes the at least one link and/or thestereoscopic visualization camera300 to approach thefirst zone5112, the rotational velocity is dynamically scaled with respect to the distance to the second zone5114. Then, when the at least one link and/or thestereoscopic visualization camera300 reach the second zone5114, the scale factor is reduced to a value of ‘0’ and all rotational joint movement toward the boundary is stopped. In other words, as therobotic arm506 and thestereoscopic visualization camera300 approach a limit or boundary, theprocessor4102 and/or therobotic arm controller4106 causes a rotational speed of at least some of joints R1 to R9 to decrease and eventually reach a velocity of ‘0’ degrees/second when the second zone5114 is reached (as shown between 20 and 30 seconds in thegraphs5102 and5104). The graph also shows that when the at least one link and/or thestereoscopic visualization camera300 are moved away from the second zone5114, theprocessor4102 and/or therobotic arm controller4106 use a scale factor value of ‘1’ since the second zone5114 is not being approached.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to cause the display monitor512 or other user interface to display one or more graphical icons representative of a status of therobotic arm506. For example, a green icon may be displayed when therobotic arm506 and/orcamera300 are located in a zone or area where scale factors have a value of ‘1’. Additionally, a yellow icon may be displayed when therobotic arm506 and/orcamera300 are located within thefirst zone5112 to indicate joint rotational speed is slowed. Further, a red icon may be displayed when therobotic arm506 reaches the second zone5114 or a boundary/limit to indicate that no further movement beyond the boundary is possible.
• Returning toFIG. 48, after the robot space boundaries are determined, theexample processor4102 and/or therobotic arm controller4106 are configured to enable therobotic arm506 for operation with the stereoscopic visualization camera300 (block4812). This may include enabling therobotic arm506 and thestereoscopic visualization camera300 to be used during a surgical procedure. This may also include enabling features, such as assisted drive and/or lock-to-target. Additionally or alternatively, this may include enabling one or more user controls at one or more of theinput devices1410 ofFIG. 41. Theexample procedure4800 ends after therobotic arm506 is enabled with thestereoscopic visualization camera300. Theexample procedure4800 may repeat if thestereoscopic visualization platform516 is reinitialized, experiences a detected failure, or the calibration cannot be validated.
D. Stereoscopic Visualization Camera and Robotic Arm Operation Embodiments
• The examplestereoscopic visualization camera300 is configured to operate in conjunction with therobotic arm506 and/or thecoupling plate3304 to provide enhanced visualization features. As discussed below in more detail, the enhanced features include an extended focus, automated focal tip positioning, providing a measurement of distances between objects in an image, providing robotic motion with conjoined visualization, sag compensation, image fusion, and storage of visualization positions/orientations. The enhanced visualization features may also include assisted-drive capability of therobotic arm506 and a lock-to-target capability that enables the camera to be locked onto a specific view while enabling an orientation of therobotic arm506 and/or thecoupling plate3304 to be changed.
1. Extended Focus Embodiment
• In some embodiments, therobotic arm506 and/or thecoupling plate3304 may provide an extended focus of thecamera300. As discussed above in connection withFIG. 43, thestereoscopic visualization camera300 includes the mainobjective assembly702 for changing a working distance. To focus on an object in the surgical site, the mainobjective assembly702 changes a focus distance from just before the object to just past the object. However, in some instances, the mainobjective assembly702 reaches a mechanical limit of the frontworking distance lens408 before the best focus is achieved.
• Theexample processor4102 and/or therobotic arm controller4106 are configured to detect when a mechanical limit is reached and/or determine that a mechanical limit is about to be reached for thelens408 and accordingly adjust a position of therobotic arm506 instead. Theprocessor4102 and/or therobotic arm controller4106 is configured to use therobotic arm506 to extend focus by computing a view vector of thecamera300 and causing therobotic arm506 to be actuated along the optical axis. Theprocessor4102 and/or therobotic arm controller4106 determine a distance needed to achieve focus using the above-described calibration parameters of thestereoscopic visualization camera300. For example, as discussed above, a position of the frontworking distance lens408 is mapped to a physical working distance of the mainobjective assembly702 to a target object. The distance provides an estimate as to how far a center of thecamera300 is from the target object. Additionally, the calibration parameters may include a mapping between motor or encoder steps for the frontworking distance lens408 to working distance to provide an estimation of distance needed to achieve a certain working distance or focus. Accordingly, theprocessor4102 and/or therobotic arm controller4106 may read a current encoder value of the frontworking distance lens408 and determine a number in meters that represents a vertical distance from thecamera300 to the target object. In other words, theprocessor4102 and/or therobotic arm controller4106 convert the lens movement (in encoder counts) into a physical distance in the robot space. Theprocessor4102 and/or therobotic arm controller4106 then determine joint rotational speeds, directions, and/or durations (e.g., a movement sequence) to that will cause therobotic arm506 to move the determined distance along the optical axis. Theprocessor4102 and/or therobotic arm controller4106 then transmits one or more signals to the appropriate joints corresponding to the movement sequence to cause therobotic arm506 to provide an extended focus. In some instances, theprocessor4102 and/or therobotic arm controller4106 may apply a scale factor before the signals are transmitted to joints R1 to R9 of therobotic arm506 and/or thecoupling plate3304.
• It should be appreciated that the extension of focus causes an automated movement of therobotic arm506. In other words, therobotic arm506 can continue motion of thecamera300 through the point of best focus. In addition, the movement of therobotic arm506 occurs without inputs from an operator to move the robotic arm, but rather, operator images regarding the changing of a focus. In some instances, theprocessor4102 and/or therobotic arm controller4106 may adjust the focus automatically to maintain a clear image.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to move therobotic arm506 along the camera's working distance in response to a single button press via theinput device1410. This feature enables an operator to fix a motor position of the mainobjective assembly702 and obtain focus by moving therobotic arm506 and/or thecoupling plate3304. This “robot auto focus” feature or procedure is accomplished by theprocessor4102 and/or therobotic arm controller4106 estimating or determining a distance from a front of the mainobjective assembly702 to a target, as discussed above in connection withFIG. 43. Theprocessor4102 and/or therobotic arm controller4106 is configured to use the determined distance with a feedback law to command a vertical velocity of the robotic arm506 (or velocity along an optical axis of the camera300) until the determined distance reaches a value of ‘0’. Theprocessor4102 and/or therobotic arm controller4106 may use this autofocus algorithm anytime during a procedure to bring a target object into focus. In some embodiments, theprocessor4102 and/or therobotic arm controller4106 may use movement of therobotic arm506 and/or thecoupling plate3304 from the last time autofocus was used as a seed or starting point when searching for a direction of autofocus, thereby improving the speed and accuracy of getting a target object into focus.
• It should be appreciated that theexample processor4102 and/or therobotic arm controller4106 may be configured to cause therobotic arm506 and/or thecoupling plate3304 to move in addition to or alternatively from moving the front lens set714, the lens barrel set718, and/or the finaloptical set742, each of which may be movable by a respective motor that has encoder counts mapped to position, focus, working distance, and/or magnification. For example, theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 to move along an optical axis when any of the front lens set714, the lens barrel set718, and/or the finaloptical set742 is about to approach a movement limit. In some examples, theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 to move first to a position that is roughly in focus or near-focus, and then adjust the front lens set714, the lens barrel set718, and/or the finaloptical set742 to bring the target image into near-ideal focus.
2. Automated Focal Tip Positioning Embodiment
• In some embodiments, therobotic arm506 and/or thecoupling plate3304 may be operated in conjunction with thestereoscopic visualization camera300 to provide automated focal tip positioning. In these embodiments, theprocessor4102 and/or therobotic arm controller4106 is configured to position thecamera300 for visualization of a target surgical site without information or feedback of a specific image and its contents. Theprocessor4102 and/or therobotic arm controller4106 may use the calibrated camera model parameters, discussed above in connection withFIGS. 42 and 49 to perform open loop camera positioning. Theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 to position thestereoscopic visualization camera300 such that a focal point or tip of the camera is in a scene. Thestereoscopic visualization camera300 determines an aiming direction for thecamera300, with respect to a coordinate system, based on calibration information regarding a pose of therobotic arm506 and/or the coupling plate and optical calibration parameters of thecamera300. Theprocessor4102 and/or therobotic arm controller4106 may characterize the aiming by a geometrically-defined view vector, which is aligned coincidentally with the stereoscopic optical axis of thecamera300, with respect to the coordinate system of therobotic arm506.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to execute an initialization routine to align calibration parameters and/or other memory data to an actual physical reference position, which may be used for tip positioning. For example, theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 and/or the coupling plate to move to a hard stop at “position 0”, where all the position data fields are set to 0 (or 0,0,0 in a three-dimensional space). Further motions are made relative to this point and the position data is updated according to, for example, encoder counts of the various joint motors of therobotic arm506 and/orcoupling plate3304.
• In other embodiments, theprocessor4102 and/or therobotic arm controller4106 may determine or set a tip position of thecamera300 based on one or more visualization parameters. For example, theprocessor4102 and/or therobotic arm controller4106 may use a center-of-projection location as a proximal end of a view vector (e.g., a “starting point” for aiming the camera300). In some surgical systems, this point on a surgical instrument is referred to as the “hind” point, and may be provided in relation to the tip. Theprocessor4102 and/or therobotic arm controller4106 calculate a view vector direction from the tip and hind points to determine an aim of thecamera300 with respect to the coordinate system of therobotic arm506.
• Additionally or alternatively, theprocessor4102 and/or therobotic arm controller4106 may determine a focus distance for calculating a range of a focus plane of a stereoscopic image from the center-of-projection. The center of the image at the focus plane is the “tip” point. Theprocessor4102 and/or therobotic arm controller4106 may use a calibrated working distance to determine the actual, spatial, physical distance from thecamera300 to the tip point. Further, theprocessor4102 and/or therobotic arm controller4106 may determine the magnification, as discussed above in regards to magnification calibration.
3. Distance Measurement Embodiment
• In some embodiments, therobotic arm506 and/or thecoupling plate3304 may be operated in conjunction with thestereoscopic visualization camera300 to provide distance measurements and/or depth measurements between objects in a stereoscopic image. For example, theprocessor4102 may determine dimensionally a center of a focal point or tip of thecamera300 with respect the coordinate system of therobotic arm506 using optical calibration parameters transformed to robot space. As discussed above in connection withFIGS. 45 and 46, a view vector and left/right parallax information of any point in an image can be used by theprocessor4102 to calculate its position in three-dimensions through triangulation with respect to the tip, or to any other point in the image. This triangulation enables theprocessor4102 to map any point in an image to the robotic coordinate system. As such, theprocessor4102 can calculate locations and/or depths of multiple objects and/or locations of different portions of an object with respect to the same coordinate space of therobotic arm506, which enables a distance measurement and/or depth measurement to be determined between the objects.
• Theprocessor4102 may cause the distance and/or depth measurement information to be displayed visually over and/or in conjunction with the stereoscopic image. In some instances, an operator may use theinput device1410 to select two or more objects by selecting the objects on a screen or pointing directly to the actual objects in the patient using a finger or surgical instrument. Theprocessor4102 receives the indication of the selection and accordingly determines the coordinates of the objects and the distances therebetween. Theprocessor4102 may then display a ruler graphic and/or values indicative of the distances (and/or an indication of the selected objects) in conjunction with the stereoscopic images.
• Further, the tracking of objects enables locations of other objects that were previously imaged (or are provided in other images) to be stored and later compared. For instance, thecamera300 may move to a location where at least some of the objects are outside of the current FOV. However, an operator can instruct theprocessor4102 to determine a distance between an object within the FOV and a previously imaged object that is currently outside the FOV.
• In some embodiments, theprocessor4102 may use the coordinates of objects for fusing digital images or models from alternate modality visualizations, such as Mill images, X-ray images, surgical templates or guidelines, pre-operative images, etc. Theexample processor4102 is configured to use object locations in the coordinate plane as well as depth information to properly scale, orientate, and position the alternate modality visualization. Theprocessor4102 may select at least a portion of the alternate modality visualization that has identical features (e.g., objects) in a displayed stereoscopic image. For instance, theprocessor4102 may use an image analysis routine to locate, in a stereoscopic image, a blood vessel pattern, a scar, a deformity, or other viewable physical structure or object. Theprocessor4102 then locates the identical features in the alternate modality visualization. Theprocessor4102 selects a portion of the alternate modality visualization that includes the identical features. Theprocessor4102 may then use coordinates, depths, and/or distances between the features in the stereoscopic image for scaling, rotating, and/or orientating the selected portion of the alternate modality visualization. The processor may then fuse the adjusted portion of the alternate modality visualization with the stereoscopic image(s). Theprocessor4102 may track how the identifiable objects move relative to each other and/or relative to the FOV to determine how the fused image is to be accordingly updated. For example, movement of thecamera300 to another surgical location may cause theprocessor4102 to select another portion of the pre-surgical image for fusion with the stereoscopic images of the other surgical location.
• In some instances, theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 to move to track a movement of an object in the FOV. Theprocessor4102 uses the coordinate position of the object to detect movement or obfuscation. In response to the detected movement or obfuscation, theprocessor4102 and/or therobotic arm controller4106 are configured to determine how therobotic arm506 and/or thecoupling plate3304 are to be moved to track the movement of the object or overcome the obfuscation. For example, theprocessor4102 and/or therobotic arm controller4106 may move therobotic arm506 in a circular path to visualize a point on a patient's retina from multiple directions to avoid reflections or obfuscation from tools.
4. Image Fusion Embodiments
• As discussed above, theprocessor4102 is configured to fuse an image from an alternate modality to live stereoscopic images. For example, if a surgeon is operating on a patient with a deep brain tumor, the surgeon can instruct that theprocessor4102 visualize an Mill image of the brain tumor in the proper location and at the proper depth and stereoscopic perspective as their live image from thecamera300 on thedisplay monitor512. In some embodiments, theprocessor4102 is configured to use distance and/or depth measurement information of one or more objects in the FOV for fusing with the alternate modality view. Theprocessor4102 may also provide for imaging fusion using the stereoscopic optical axis (e.g., view vector), the IPD, and/or the camera model parameters that were calculated in the calibration steps discussed in connection withFIG. 42 and stored to one or more LUTs. The use of the optical calibration parameters enables theprocessor4102 to display an alternate modality image as if the image was acquired by thestereoscopic visualization camera300. Theprocessor4102 may use the optical calibration parameters of the camera to model, scale, or modify alternate modality images based on an effective IPD of thecamera300 such that the alternate modality image is viewed at a distance Z from a focus point in the surgical site, given the applied working distance and magnification of thecamera300.
• FIG. 52 shows a diagram of anexample procedure5200 for fusing an image from an alternate modality visualization with stereoscopic image(s), according to an example embodiment of the present disclosure. Although theprocedure5200 is described with reference to the flow diagram illustrated inFIG. 52, it should be appreciated that many other methods of performing the steps associated with theprocedure5200 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure5200 may be performed among multiple devices including, for example theoptical elements1402, theimage capture module1404, the motor andlighting module1406, theinformation processor module1408 of the examplestereoscopic visualization camera300 ofFIG. 14 and/or joints R1 to R9 androbotic arm controller4106 ofFIG. 41. For example, theprocedure5200 may be performed by a program stored in thememory1570 of theprocessor4102.
• Theexample processor4102 ofprocedure5200 is configured to use optical calibration parameters to render, for example, previously generated three-dimensional MRI data of a patient as a stereoscopic image with proper perspectives as a stereoscopic image recorded by thecamera300. Theprocessor4102 may receive, for example, an alternate modality visualization, such as the MRI data, fromdevice4104 ofFIG. 41 (block5202). Theprocessor5202 may also receive aninput5203 via aninput device1410 indicative that the alternate modality visualization is to be fused with stereoscopic images recorded by the stereoscopic visualization camera300 (block5204).
• During theprocedure5200, when a surgeon positions thecamera300 at a desired orientation and position for a surgical procedure, posedata5205 is obtained by the processor4102 (block5206). Thepose data5201 may include positions of therobotic arm506, thecoupling plate3304, and/or thestereoscopic visualization camera300. Theprocessor4102 also accesses magnification and working distanceoptical calibration parameters5207 related to thecamera300 from one or more LUTs, such as theLUTs4203 ofFIG. 42 (block5208). Theprocessor4102 uses thepose data5205 in conjunction with the magnification and working distanceoptical calibration parameters5207 to determine a stereoscopic axis and IPD for the camera300 (block5210). Theprocessor4102 applies the pose data, stereoscopic axis data, IPD data, and/or the optical calibration parameters to select at least a portion of the MRI data and/or modify, scale, orientate, partition, etc. the selected portion of the MRI data such that the selected portion is provided at a perspective of a view of the patient's brain as viewed by the stereoscopic visualization camera300 (block5212). Theprocessor4102 is configured to apply the stereoscopic optical axis view vector and IPD for rendering the selected portion of MRI data into a stereoscopic image corresponding to the current live view of the camera300 (block5114). Theprocessor4102 may then fuse the stereoscopic MRI image with live stereoscopic image(s) from thecamera300, as discussed herein (block5216).
• As discussed above, theprocessor4102 may use an object or feature for positioning or fusing the rendered MRI data with the stereoscopic image(s) from thestereoscopic visualization camera300. For example, theprocessor4102 may use one or more image analysis routines for identifying distinct features or objects in a stereoscopic image, locating the same distinct features in the rendered stereoscopic MRI data, and laying the rendered stereoscopic MM data over the appropriate portion of the camera stereoscopic image(s) such that the features or objects are aligned and have the same scale, size, depth, orientation, etc. Theprocessor4102 may make the rendered stereoscopic MM data at least partially transparent to enable the live image(s) to also be viewable. Additionally or alternatively, theprocessor4102 may adjust a shading at a border of the rendered stereoscopic MM data to reduce visual contrasts between the rendered stereoscopic MRI data and the camera stereoscopic image(s). Theexample procedure5200 ofFIG. 52 may then end.
• Theexample procedure5200 enables the brain tumor to be visualized by the surgeon in an accurate location relative to the stereoscopic images of thecamera300. The surgeon may use this fusion visualization especially partway through a surgical procedure. For example, the surgeon can see the as yet unexposed tumor in a manner best described as “x-ray vision” below a current level of dissection. Control of the transparency of live or rendered stereoscopic MRI images may be adjusted via theinput device1410 to optimize clarity of the fused image. The example procedure accordingly enables a safer, more accurate and efficient excision of a tumor.
• In some embodiments, theprocedure5200 may be repeated if a FOV, focal point, working distance, and/or magnification changes. In these embodiments, theprocessor4102 is configured to use the updated pose information and extract the corresponding stereoscopic axis and IPD from a lookup table to re-render the Mill data into an updated, accurate stereoscopic image. Theprocessor4102 is configured to fuse the newly rendered MM data into the current stereoscopic images such that the live view and the corresponding Mill data are located in the proper position, depth, and orientation.
• In some embodiments, theexample processor4102 is configured to operate with thestereoscopic visualization camera300, therobotic arm506, and/or thecoupling plate3304 to generate live cross-sectional fused visualizations. A cross-section visualization of a surgical site provides a surgeon a significantly improved viewpoint that is not otherwise available.FIG. 53 shows a diagram of apatient5300 with aglioblastoma5302, which is illustrated in phantom inside of a patient's head. Specifically, theglioblastoma5302 may be located in the patient'sbrain5304, which is shown in light phantom lines. The diagram ofFIG. 53 is typical of pre-operative diagnostic images, for example, from an MM device, where numerous image slices are stacked and a 3D model of an interior of the patient'scranium5306 is rendered and visualized.
• In the illustrated example, theglioblastoma5302 is to be removed through brain surgery.FIG. 54 shows a diagram of a perspective view of thepatient5300 undergoing acraniotomy procedure5400 to provide access to thecranium5306. Theprocedure5400 also includes brain dissection and retraction usingsurgical instrument5402. Generally, asurgical access site5404 is made in a deep conical shape to access theglioblastoma5302.
• FIG. 55 shows a diagram of thestereoscopic visualization platform516 including thestereoscopic visualization camera300 and therobotic arm506 to visualize thecraniotomy procedure5400, according to an example embodiment of the present disclosure. As illustrated, thecraniotomy procedure5400 is set up such that therobotic arm506 is positioned to aim thestereoscopic visualization camera300 through the top of thecranium5306 alongvisualization axis5500 of the conicalsurgical site5404. A view of the operating surgeon is generally through the top of thecranium506, as shown inFIG. 57. As one can appreciate fromFIG. 7, the depth of the surgery and, for example, the tip of thesurgical instrument5402 is difficult to see.
• The examplestereoscopic visualization camera300, shown inFIG. 55, provides a highly accurate stereoscopic image viewed down theaxis5500 of the conical surgical access site. As discussed above, parallax information between left and right views of thecamera300 for all points common to both views in the access site are used by theprocessor4102 to determine a depth of each point from a known reference depth, such as for example, the object plane. In the illustrated example, parallax between the left and right views is equal to a value of ‘0’, which enables theprocessor4102 to determine a depth map of each point in the image. The depth map can be re-rendered by theprocessor4102 as if the map was viewed from a different angle. Further, theprocessor4102 is configured to make at least a portion of the depth map transparent, upon receiving an instruction from a surgeon and/or an operator. In the illustrated example, a portion of the depth map below section plane AA ofFIG. 57 can be made transparent by theprocessor4102, thereby enabling theprocessor4102 to generate a cross-sectional view of the livesurgical access site5404.
• FIG. 56 shows a diagram of a phantom view of the conically shapedsurgical access site5404. The illustratedsurgical access site5404 includes stepped conical segments for clarity in this discussion. In this example a swept cone angle of thesite5404 is designated by angle ‘α’.
• FIG. 58 shows a diagram of the conically shapedsurgical access site5404 for thecraniotomy procedure5400. Prior knowledge of the size and shape of thesurgical instrument5402, along with image recognition of its position, direction, and/or orientation enable theprocessor4102 to generate image data for the cross-sectional view shown inFIG. 58. Recognition of theinstrument5402 in the stereoscopic view represented byFIG. 57 enables its precise placement in the cross-sectional view ofFIG. 58 and visualization of, for example, the underside of the instrument which is not visible to the surgeon while operating on the patient'sbrain5304.
• In some embodiments, theprocessor4102 is configured to fuse an image of theglioblastoma5302 with near-live or live stereoscopic image(s). As discussed above, the combination of therobotic arm506 and thecamera300 provides highly accurate position, direction, and/or orientation information of a view with respect to the robot frame of reference or robot space. After registration or calibration of therobotic arm506 and thecamera300 to the frame of reference of thepatient5300, accurate position, direction, and/or orientation information of thesurgical access site5404 and its respective position to the patient is generated by theprocessor4102. Theprocessor4102 uses image fusion to superimpose a selection portion of the MRI image of theglioblastoma5302 on to a cross-sectional view, as shown inFIG. 59. In addition, the image fusion enables the visualization of other relevant MRI image data including, for example, brain vasculature or other structure desired to be included in the image. The exemplary surgical procedure proceeds with the surgeon being able to see and understand the depth location of theglioblastoma5302 in addition to a safe spacing or positioning of theinstrument5402.
• FIG. 59 shows a diagram of a sectional view of thesurgical access site5404. In this example, aportion5302′ of theglioblastoma5302 is visible to thestereoscopic visualization camera300.FIG. 60 shows a diagram of a cross-section view orthogonal to plane AA ofFIG. 57. The diagram may be illustrative of a cross-sectional view generated by theprocessor4102 based on the MRI data fused with the live view of thesurgical access site5404. The use of the depth map by theprocessor4102 enables rendering of thesurgical access site5404 at various desired section planes and combinations of section planes, as shown inFIG. 61. The rendering enablesprocessor4102 to display thecomplete glioblastoma5302 including thevisible portion5402′ and the reminder from the MRI data. Theprocessor4102 may display the visualization from a perspective of thecamera300 or as a cross-sectional view, as shown inFIG. 61.
5. Robotic Motion with Conjoined Visualization Embodiment
• In some embodiments, theexample processor4102 operates in connection with therobotic arm controller4106, thestereoscopic visualization camera300, therobotic arm506, and/or thecoupling plate3304 to conjoin visualization with robotic motion. In some examples, theprocessor4102 and/or therobotic arm controller4106 operate in a closed loop to provide conjoined visualization based on robotic motion. In these examples, theprocessor4102 and/or therobotic arm controller4106 are configured to position therobotic arm506, thecoupling plate3304, and/or thecamera300 for visualization of a surgical site based on a specific image and its contents (e.g., objects, identifiable features, etc.). As discussed above, therobotic arm506 andcamera300 positions are known by theprocessor4102 and/or therobotic arm controller4106. In addition, image data recorded by the camera is stereoscopic, which provides depth data. As a result, theprocessor4102 and/or therobotic arm controller4106 can determine a location on a patient or in robot three-dimensional space of every visualized point. Thus, when therobotic arm506 moves thecamera300 in a desired direction from an initial position with an initial image, the desired image change is expected to be seen in a second, post-move image.
• Alternatively, the expected post-move image can be calculated by theprocessor4102 and/or therobotic arm controller4106 being configured to apply equations representative of the desired move to the initial image data, which results in a calculated second image. Theprocessor4102 and/or therobotic arm controller4106 compare the post-move actual image with the calculated image using a match-template routine or function, as described above. If errors are detected, theprocessor4102 and/or therobotic arm controller4106 can correct the errors by moving therobotic arm506 and/or thecamera300 accordingly. For example, given an initial image and a desired move “100 pixels to the right” received from an operator, the image data for the theoretical moved image can be calculated as a shift of 100 pixels right by theprocessor4102 and/or therobotic arm controller4106. Then, the physical move is made by performing commands to the various coordinated robot joints, as disclosed, to relocate therobotic arm506 and/or thecamera300 to the theoretical desired location. A second image is recorded by thecamera300, which is compared by theprocessor4102 and/or therobotic arm controller4106 to the calculated image data using, for example a match template function or its equivalent. If the move is accurate, the data would indicate a 100% correlation at a tip of thecamera300, where both images are perfectly aligned. If, however, the actual image data shows best correlation at another location, for example 101 pixels right and 5 pixels up, then the move could be modified by theprocessor4102 and/or therobotic arm controller4106 to correct the error by physically moving thecamera300, via therobotic arm506, 1 pixel left and 5 pixels down.
6. Sag Compensation Embodiment
• In some embodiments, at least some of joints R1 to R9 of therobotic arm506 and/or thecoupling plate3304 may experience some sag. Theprocessor4102 and/or therobotic arm controller4106 may be configured to provide correction for robotic arm sag. In some instances, theprocessor4102 and/or therobotic arm controller4106 are configured to perform sag compensation on a series of small moves, such that motion accuracy is preserved over a range of motion of therobotic arm506. For example, to characterize and eliminate sag, sag compensation is performed in motion directions that exercise a particular robotic joint to isolate error as a function of actual robot joint rotational position. By comparing the error to torque moments calculated by multiplyingcamera300 load weight by moment arm (or link) length, the compliance of that joint can be determined. Alternatively, joint compliance may be calculated using analytical techniques, for example Finite Element Analysis (“FEA”).
• Using and storing the above-compliance characterization for all the joints in all rotational positions, theprocessor4102 and/or therobotic arm controller4106 may calculate the overall sag for a particular camera position. Theprocessor4102 and/or therobotic arm controller4106 may determine a sag correction factor for each camera position to a LUT and/or calibration registers. Further, theprocessor4102 and/or therobotic arm controller4106 may apply the sag correction factor to robotic arm move commands or a movement sequence (before or after scale factors are applied) such that sag compensation is incorporated into movement commands/signals. The correction factor may be calculated in an ongoing motion procedure, thereby enabling accurate tracking and following of thecamera300. This correction factor further eliminates a need for a second camera for calibration/positioning of thestereoscopic visualization platform516, and eliminates the need to have fiducial targets on thecamera300, and hence eliminates a problem of drape interference.
7. Storage of Visualization Positions/Orientations Embodiment
• In some embodiments, theexample processor4102 is configured to save visualization parameters to return to a certain orientation and/or position of thestereoscopic visualization camera300. The visualization parameters may include a view vector, location, magnification, working distance, focus, position, and/or orientation of thestereoscopic visualization camera300, therobotic arm506 and/or thecoupling plate3304.
• In an example, a surgeon may wish to have a highly-magnified visualization of a small suture during an anastomosis of a portion of a blood vessel under visual illumination. The surgeon may then zoom-out to a wider view of the entire vessel under infrared illumination to check for patency. The surgeon may then return to the magnified visualization to complete the suture. In this example, theprocessor4102 is configured to save the visualization parameters at each of the positions. Theprocessor4102 may store positions corresponding to locations that have been continuously viewed for a time period, such as two seconds, five seconds, thirty seconds, etc. Theprocessor4102 may also store a position after receiving an instruction from the surgeon via theinput device1410.
• Theprocessor4102 may display a list of stored locations and/or waypoints. Selection of a stored location causes theprocessor4102 and/or therobotic arm controller4106 to move the robotic arm and/or thecoupling plate3304 to the previous location and adjust optical parameters, including light illumination and filtering, as set previously. Such a configuration enables a surgeon to seamlessly view all stored locations in sequence without removing their eyes from a displayed image of the procedure or removing their hands and their instruments from the site.
• In some embodiments, theprocessor4102 may be configured to enable an operator to create waypoints or positions/orientations prior to a surgical procedure. The waypoints may be provided in a sequence, which enables theprocessor4102 to progress through the specified waypoints during the procedure after receiving an input from an operator to progress. Theprocessor4102 may provide a three-dimensional representation of therobotic arm506, thecoupling plate3304, and/or thecamera300 via thetouchscreen input device1410ato enable an operator to virtually position thestereoscopic visualization platform516. This may include providing for a magnification, working distance, and/or focus in relation to a virtualized patient and/or based on alternate modality visualizations of the patient. Theprocessor4102 is configured to store the visualization parameters to, for example, thememory1570 and/or thememory4120 for each waypoint.
• In some embodiments, theprocessor4102 is configured to perform certain visualizations that are particular to certain procedures. For example, image recognition functionality in theprocessor4102 is used to automatically align thecamera300 with an object of interest. The image of the surgical site is compared by theprocessor4102 to a previous image or image of the target object to provide for recognition of a desired object and its position and orientation within a stereoscopic image. Theprocessor4102 and/or therobotic arm controller4106 are configured to, for example, move therobotic arm506 toward the object and zoom thecamera300 towards the object and set the desired image view attributes for the particular object and procedure. For instance, in ophthalmology, a live retinal image can be compared to a saved image such that, for example, the optic nerve head of the patient's retina can be located from the image recognition. Theprocessor4102 and/or therobotic arm controller4106 then automatically move therobotic arm506 and/or thecoupling plate3304 and focus and/or change a magnification of thecamera300 such that the tip of thecamera300 is pointed at the nerve head for diagnosis. Theprocessor4102 may then set thecamera300 and/or themonitor512 for image display without red coloration to enable features of the retina to be more easily distinguished from surrounding tissue.
• In addition to saving and returning to stored visualizations, paths of motion from one view to another can also be saved by the example processor. In the anastomosis example discussed above, theprocessor4102 and/or therobotic arm controller4106 may cause therobotic arm506 and/or thecamera300 to follow an entire length of a blood vessel under high magnification to check for aneurysms or other conditions. Theprocessor4102 may be configured to recognize and follow the continuous vessel, as desired. Theprocessor4102 may perform a match template routine on a limited set of pixels to actively determine the direction of motion of therobotic arm506 and/or thecamera300.
• Theexample processor4102 may also program and store a path of motion within a visualization of an object, made from different viewing angles. For example, an ophthalmological gonioscopy of a patient's eye can be performed by programming theprocessor4102 and/or therobotic arm controller4106 to pivot about a point inside the eye. In this example, therobotic arm506 sweeps thecamera300 in a generally conical motion such that the patient's eye is viewed from a plethora of viewing angles. Such motion of surgical site visualizations can be used to select the best angle to preclude spurious reflections from illumination or to see around obstructions in alternative viewing angles.
• In some embodiments, theprocessor4102 is configured to reduce occlusions in depth map calculations. Occlusions are inherent in depth map calculations due to the parallax of the two views of a stereoscopic image, where a first view sees some portion of a site different from the other view. As a result, each view does not see some part of the other view. By moving therobotic arm506 among various places and recalculating the depth map while using knowledge of the three-dimensional locations of the image pixels, occlusion is reduced. The depth map may be made more accurate by iteratively calculating the map after known motion steps are performed, anticipated map changes are calculated, errors are determined by the difference, and an average map is constructed.
E. Assisted Drive Embodiments
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to execute one or more algorithms, routines, etc. defined by instructions stored in thememory1570 and/or4120 to enable therobotic arm506 and/or thecoupling plate3304 to provide powered joint movement based on detected forces applied by an operator for moving thestereoscopic visualization camera300. In these embodiments, the assisted drive feature enables therobotic arm506 to operate as an extension of a surgeon by moving thestereoscopic visualization camera300 to a desired location and/or orientation. As described below, theprocessor4102 and/or therobotic arm controller4106 are configured to monitor force/torque/movement imparted by an operator and positions of arm joints to infer an operator's intent and accordingly move therobotic arm506 and/or thecoupling plate3304.
• FIG. 62 shows a diagram that is illustrative of an algorithm, routine, orprocedure6200 for providing assisted drive of thestereoscopic visualization camera300, according to an example embodiment of the present disclosure. Although theprocedure6200 is described with reference to the flow diagram illustrated inFIG. 62, it should be appreciated that many other methods of performing the steps associated with theprocedure6200 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure6200 may be performed among multiple devices including, for example theinformation processor module1408 of the examplestereoscopic visualization camera300 ofFIG. 14 and/or joints R1 to R9 androbotic arm controller4106 ofFIG. 41. In some examples, theprocedure6200 may be performed by a program stored in thememory4120 of therobotic arm controller4106. Theexample procedure6200 may be executed periodically as force is applied to thecamera300. For example, theprocedure6200 may sample force/torque data every update cycle, which may be 1 (“ms”), 5 ms, 8 ms, 20 ms, 50 ms, etc.
• In the illustrated embodiment, theprocessor4102 and/or therobotic arm controller4106 receive force/torque output data6201 from thesensor3306 related to force imparted by an operator on thecamera300. Theprocessor4102 and/or therobotic arm controller4106 are configured to filter the received output data6201 (block6202). The output data may include a force and/or torque vector. The filtering may include applying a first low-pass filter, a second low pass filter, and/or a notch filter that targets cart vibrations. In other examples, a single low-pass filter and a notch filter may be used by theprocessor4102 and/or therobotic arm controller4106.
• Theexample processor4102 and/or therobotic arm controller4106 also receivejoint position data6203 from one or more joint sensors in therobotic arm506 and/or thecoupling plate3304. Theprocessor4102 and/or therobotic arm controller4106 use thejoint position data6203 to provide compensation for the filtered force/torque output data (block6204). The compensation may include gravity compensation and/or force-application point compensation. For gravity compensation, the effects of Earth's gravity are removed from the filtered data. For force-application point compensation, theprocessor4102 and/or therobotic arm controller4106 provide compensation to the filtered data (and/or gravity compensated data) based on a point where the force was applied to the camera300 (e.g., the control arms304). As discussed above in connection withFIG. 35, thesensor3306 is located some offset distance away at an angle from the control arms304. The offset distance and angle cause the force applied at the control arms304 to be slightly shifted by direction and angle when detected in thesensor3306. The force-application compensation adjusts the force values as though the force was applied directly to thesensor3306 instead of the control arms304. The force-application compensation may be pre-determined based on a known angle and/or distance between thesensor3306 and the control arms304. Together, the gravity compensation and the force-application point compensation modify the filtered force/torque data to create a force/torque vector that is proportional to the force/torque provided by an operator at the control arms304 of the camera.
• Theexample processor4102 and/or therobotic arm controller4106 also use thejoint position data6203 in conjunction with the compensated, filtered force/torque output data to perform a coordinate transform between force/torque frame to a global frame or robot space (block6206). The transform may include one or more predefined equations or relations based on the known robot space and the orientation of thesensor3306. Theexample processor4102 and/or therobotic arm controller4106 also use thejoint position data6203 to perform a coordinate transform between a camera frame of thestereoscopic visualization camera300 and the global frame or robot space (block6208). The coordinate transform for the camera frame may be based on the optical calibration parameters mapped to robot space of therobotic arm506, as described above.
• After performing the coordinate transforms, theexample processor4102 and/or therobotic arm controller4106 are configured to convert the force/torque vector(s) into one or more translational/rotational vectors using at least one sigmoid function (block6210). The creation of the translational/rotational vector(s) produces an inference of an intended direction of the operator. The translational and rotational information is used to determine how joints of therobotic arm506 are to be rotated to mirror, match, and/or approximate the operator's intended movement.
• In some examples, theexample processor4102 and/or therobotic arm controller4106 are configured to apply robot speed scaling to the translational/rotational vector(s) (block6212). The speed scaling may be based, for example, on operating conditions ofrobotic arm506. For example, speed scaling may be applied based, for example, once a surgical procedure has started to prevent the arm from accidently striking operating room staff, instruments, and/or the patient at a relatively high rate of speed. When a procedure has not yet begun, theexample processor4102 and/or therobotic arm controller4106 may apply less speed scaling for calibration or setting of therobotic arm506 when a patient is not present.
• Theexample processor4102 and/or therobotic arm controller4106 determine potential movement sequences of joints of therobotic arm506 based on the scaled translational/rotational vector(s). While evaluating possible sequences, theprocessor4102 and/or therobotic arm controller4106 identify joint singularities for avoidance, thereby ruling out the corresponding movement operations of the robotic arm506 (block6214). As discussed above, singularities may include elbow lock or other positions that may be prone to hysteresis and backlash. Theprocessor4102 and/or therobotic arm controller4106 are configured to select a movement sequence, after movement singularities are eliminated using, for example, Jacobian kinematics (e.g., an inversion of a Jacobian matrix) (block6216). The Jacobian kinematic equations define how certain joints of therobotic arm506 and/or thecoupling plate506 are to be moved based on the scaled translational/rotational vector(s). The Jacobian kinematics provide for velocity control while inverse kinematics, discussed below, provide for positional control. In some embodiments, theprocessor4102 and/or therobotic arm controller4106 may instead use inverse kinematics or other robotic arm control routines. Theprocessor4102 and/or therobotic arm controller4106 determine a movement sequence that specifies how certain joints of the robotic arm and/orcoupling plate3304 are to move in a coordinated manner and specifies, for example, joint rotation speed, joint rotational direction, and/or joint rotational duration. The movement sequence may also specify a sequence in which joints of therobotic arm506 and/or thecoupling plate3304 are to be rotated. Any of joints R1 to R9 of the robotic arm and/orcoupling plate3304 may rotate individually or have overlapping movement depending on the movement sequence.
• After a movement sequence is determined, theprocessor4102 and/or therobotic arm controller4106 are configured to perform collision avoidance using joint speed scaling and/or boundaries. For example, theprocessor4102 and/or therobotic arm controller4106 are configured to determine if the movement sequence will cause one or more joints and/or links of therobotic arm506 and/or thecoupling plate3304 to approach a boundary or other defined Cartesian limit, such as space around a patient or instrument. As discussed above in connection withFIG. 49, theprocessor4102 and/or therobotic arm controller4106 may compare estimates of positions of the links and/or joints in the robot space from the movement sequence to one or more defined boundaries and/or angle limits. Based on a distance from a boundary, theprocessor4102 and/or therobotic arm controller4106 applies one or more joint speed limits via a scale value (block6218). Theprocessor4102 and/or therobotic arm controller4106 may also apply one or more joint position limits (block6220) that prevent, for example, links of therobotic arm506 from striking each other and/or prevent therobotic arm506, thecoupling plate3304, and/or thecamera300 from extending past a boundary. Locations just before position limits (e.g., 1 centimeter (“cm”) 2 cm, 10 cm, etc. before a position limit) and/or locations at the position limits may correspond to locations in Cartesian robot space where a value of the scale factor is ‘0’.
• In some examples, theprocessor4102 and/or therobotic arm controller4106 may perform Jacobean kinematics with the boundaries provided as an input to the equations, where movement through areas close to a boundary are provided a higher cost factor. The use of boundary cost factors causes theprocessor4102 and/or therobotic arm controller4106 to avoid locations close to boundaries, if possible, when determining a movement sequence. The cost factor may include inversely proportional to a decrease in a scale factor associated with a particular location in robot space. The scale factor may apply to each joint/link, or separate scale factors may exist for each joint for the same location in robot space.
• After providing for collision avoidance, theexample processor4102 and/or therobotic arm controller4106 are configured to provide for correction for relatively fast reversals of the robotic arm506 (block6222). Theprocessor4102 and/or therobotic arm controller4106 may implement a zero phase delay algorithm to reject directional impulses that quickly cause one or more joints to change rotational direction. The zero phase delay algorithm may be implemented by a filter that prevents, for example, the robotic arm from bucking or rocking if an operator reverses direction too quickly.
• As illustrated inFIG. 62, theexample processor4102 and/or therobotic arm controller4106 are configured to validate commands of the movement sequence (block6224). Theprocessor4102 and/or therobotic arm controller4106 may validate a command to ensure that a command (or signal indicative of a command) is within operating parameters (e.g., duration, rotational speed, etc.) of a joint motor. Theprocessor4102 and/or therobotic arm controller4106 may also validate a command by comparing the command to current thresholds to ensure therobotic arm506 will not draw excess current during any phase of the movement sequence.
• Theexample processor4102 and/or therobotic arm controller4106 may also apply one or more anti-noise filters to the movement commands or signals indicative of the movement commands (block6226). The filter may include a high frequency low-pass filter that removes high frequency noise components, which may induce transient signals in a joint motor. After any filtering, theprocessor4102 and/or therobotic arm controller4106 transmit the one or more commands via one or more signals or messages to the appropriate joint motor of therobotic arm506 and/or thecoupling plate3304 according to the movement sequence (block6228). The transmitted commands cause motors at the respective joints to move therobotic arm506 and/or thecoupling plate3304, thereby causing thecamera300 to move as intended by the operator. Theexample procedure6200 may repeat as long as an operator applies force to thecamera300.
• FIG. 63 shows a diagram of anexample procedure6300 for moving theexample visualization camera300 using aninput device1410, according to an example embodiment of the present disclosure. Theexample procedure6300 is nearly identical to theprocedure6200 ofFIG. 62, exceptblocks6202 to6206 related to thesensor3306 are removed. In the illustrated example, acontrol input6301 is received from aninput device1410, such as buttons on the control arm304, a foot pedal, joystick, touchscreen interface, etc. Thecontrol input6301 is indicative of directional movement of the camera in the Cartesian robot space of therobotic arm506.
• As illustrated inFIG. 63, thecontrol input6301 is combined with thejoint position data6203 from one or more joint sensors in therobotic arm506 and/or thecoupling plate3304 for performing a coordinate transform from a camera frame to a global frame and/or robot space (block6208). Theexample procedure6300 then continues in the same manner as discussed forprocedure6200. Theprocessor4102 and/or therobotic arm controller4106 accordingly cause therobotic arm506, thecoupling plate3304, and/or thecamera300 to move to a desired location and/or orientation based on thecontrol input6301 received from theinput device1410.
F. Lock-to-Target Embodiments
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 are configured to execute one or more algorithms, routines, etc. defined by instructions stored in thememory1570 and/or4120 to enable therobotic arm506 and/or thecoupling plate3304 to provide a lock-to-target feature. In these embodiments, the lock-to-target feature enables therobotic arm506 to operate as an extension of a surgeon by enabling thestereoscopic visualization camera300 to be re-oriented while being locked onto a target surgical site. As described below, theprocessor4102 and/or therobotic arm controller4106 are configured to monitor force/torque/movement imparted by an operator and positions of arm joints to infer an operator's intent and accordingly re-orientate therobotic arm506 and/or thecoupling plate3304 such that the focal point of thecamera300 remains locked or stationary.
• The lock-to-target feature enables thecamera300 to be reoriented by causing all motion to be constrained to the surface of a virtual sphere. The tip of thecamera300 is located at an outer surface of the virtual sphere (e.g., a top hemisphere of the virtual sphere) and a focal point of thecamera300 or target surgical site constitutes a center of the virtual sphere. Theexample processor4102 and/or therobotic arm controller4106 enable an operator to move thecamera300 over an outer surface of the virtual sphere while keeping thecamera300 pointed at the center of the sphere, thereby keeping the target surgical site in focus during the movement. The lock-to-target feature enables an operator to easily and quickly obtain significantly different views of the same target site.
• FIG. 64 shows a diagram that is illustrative of an algorithm, routine, orprocedure6400 for providing a lock-to-target for thestereoscopic visualization camera300, according to an example embodiment of the present disclosure. Although theprocedure6400 is described with reference to the flow diagram illustrated inFIG. 64, it should be appreciated that many other methods of performing the steps associated with theprocedure6400 may be used. For example, the order of many of the blocks may be changed, certain blocks may be combined with other blocks, and many of the blocks described are optional. Further, the actions described inprocedure6400 may be performed among multiple devices including, for example theinformation processor module1408 of the examplestereoscopic visualization camera300 ofFIG. 14 and/or joints R1 to R9 androbotic arm controller4106 ofFIG. 41. In some examples, theprocedure6400 may be performed by a program stored in thememory4120 of therobotic arm controller4106.
• Theexample procedure6400 is similar to the assisteddrive procedure6200. However, theprocedure6400 provides for the commanding of joint positions to retain a focal point of thecamera300 while theexample procedure6200 provides for the calculation of joint velocities. Theexample procedure6400 determines a desired force/movement vector input by an operator and calculates a rotational transform such that the focal point of thecamera300 remains stationary while one or more joints of therobotic arm506 and/or thecoupling plate3304 are moved to re-orient thecamera300. The reorientation of thecamera300 enables a target surgical site to be imaged from different angles. The reorientation may be needed when a first view path is blocked by, for example, an instrument, and the surgeon desires to maintain the current focal point.
• Theexample procedure6400 begins when an operator selects lock-to-target button on theinput device1410, which causes an instruction message or signal to be transmitted to theprocessor4102 and/or therobotic arm controller4106. After receiving the message, theprocessor4102 and/or therobotic arm controller4106 operate in a lock-to-target mode where the working distance and/or focal point is held stationary while enabling an operator to change an orientation of thecamera300, which causes one or more joints of the robotic arm and/orcoupling plate3304 to provide assisted movement. When an instruction is received, theexample processor4102 and/or therobotic arm controller4106 may record the current working distance, magnification, focus, and/or other optical parameters of thecamera300. Theprocessor4102 and/or therobotic arm controller4106 may also record a current image of the FOV.
• After theprocedure6400 begins, theprocessor4102 and/or therobotic arm controller4106 receive force/torque output data6201 from thesensor3306 related to force imparted by an operator on thecamera300. As discussed in connection withFIG. 62, theprocessor4102 and/or therobotic arm controller4106 filter and provide gravity/force-application compensation for the data6102 (blocks6202 and6204). Also similar toFIG. 62, theprocessor4102 and/or therobotic arm controller4106 use thejoint position data6203 in conjunction with the compensated, filtered force/torque output data to perform a coordinate transform between force/torque frame to a global frame or robot space (block6206). Theexample processor4102 and/or therobotic arm controller4106 also use thejoint position data6203 to perform a coordinate transform between a camera frame of thestereoscopic visualization camera300 and the global frame or robot space (block6208). Theexample processor4102 and/or therobotic arm controller4106 also perform a transform from the global frame or robot space to spherical coordinates that correspond to a virtual sphere (block6410).
• After the coordinate transforms, theexample processor4102 and/or therobotic arm controller4106 are configured to scale trajectory speed based, for example, on an operation mode of the camera300 (block6412). The scaling may be similar to the scaling performed atblock6212 ofFIG. 62. Theexample procedure6400 ofFIG. 64 continues by theprocessor4102 and/or therobotic arm controller4106 calculating a sphere end point (block6414). Calculation of the sphere end point provides an inference about the operator's desired movement direction and determines how far thecamera300 is to be moved over the virtual sphere without rotating the sphere.
• FIG. 65 shows a diagram that is illustrative of avirtual sphere6500 for the lock-to-target feature, according to an example embodiment of the present disclosure. As shown inFIG. 65, thestereoscopic visualization camera300 is virtually placed on thesphere6500 based on a current position, as determined from thejoint position data6203. A view vector of thecamera300 points to a tip, designated as the xyz target, which is located in a center of thesphere6500. Theprocessor4102 and/or therobotic arm controller4106 are configured to use the transformed force/torque data to determine how thecamera300 on the sphere is to move along a surface of thesphere6500 while maintaining the view vector pointed at the xyz target, where any given point on the sphere is given by an equation that is a function of rotational sphere angles ‘v’ and ‘u’. When the force/torque data is used, theprocessor4102 and/or therobotic arm controller4106 use an ‘x’ and ‘y’ component corresponding to the translational force for directly determining how thecamera300 is to move on thevirtual sphere6500 to determine the sphere end point.
• Theprocessor4102 and/or therobotic arm controller4106 may determine the sphere end point differently for different inputs. For example, if an input is received via theinput device1410, as shown inFIG. 63, theprocessor4102 and/or therobotic arm controller4106 converts ‘up’, ‘down’, ‘left’, and ‘right’ from camera coordinates to robot space coordinates, which are provided as x,y vectors. Similar to the force/torque data, the x,y vectors are used by theprocessor4102 and/or therobotic arm controller4106 for directly determining how thecamera300 is to move on thevirtual sphere6500 to determine the sphere end point. It should be appreciated that in instances where inputs are received via the input device, the operations discussed in conjunction withblocks6202 to6206 may be omitted, as shown inFIG. 63.
• In some examples, theprocessor4102 and/or therobotic arm controller4106 are configured to receive orbit input data. In these examples, theprocessor4102 and/or therobotic arm controller4106 hold the sphere angle ‘v’ constant while iterating movement along sphere angle ‘u’ of thevirtual sphere6500. The iterative movement along sphere angle ‘u’ enables the sphere end point to be determined for the orbit input. It should be appreciated that while the inputs are applied to thevirtual sphere6500, in other examples, the inputs may be applied to other shapes. For example, thevirtual sphere6500 instead may be defined as a virtual cylinder, an ellipsoid, an egg-shape, a pyramid/frustum, etc.
• In other examples, theprocessor4102 and/or therobotic arm controller4106 are configured to receive level scope input data. In these examples, theprocessor4102 and/or therobotic arm controller4106 hold the sphere angle ‘u’ constant while iterating movement along sphere angle of thevirtual sphere6500. The iterative movement along sphere angle ‘v’ causes thecamera300 to be moved to a top of thevirtual sphere6500.
• Returning toFIG. 64, after the sphere end point is determined, theprocessor4102 and/or therobotic arm controller4106 are configured to calculate an amount of rotation needed for thecamera300 to maintain the lock at the x,y,z target after thecamera300 has been moved along the virtual sphere to the determined end point (block6416). Theprocessor4102 and/or therobotic arm controller4106 may also provide anti-yaw correction during this calculation (block6418). In other words, theprocessor4102 and/or therobotic arm controller4106 are configured to determine how thecamera300 is to be orientated given its new position on thevirtual sphere6500 such that the view vector or tip of thecamera300 is provided at the same x,y,z target, which is pointed at a center of thevirtual sphere6500, which corresponds to a target surgical site or focal point.
• During this step, theprocessor4102 and/or therobotic arm controller4106 determine the joint angles of therobotic arm506 and/or thecoupling plate3304 needed to achieve the desired orientation. After the x,y,z sphere end point is calculated inblock6414, theprocessor4102 and/or therobotic arm controller4106 determine roll and pitch amounts for thecamera300. In some embodiments, the calculation is a two-step process. First, theprocessor4102 and/or therobotic arm controller4106 calculate an initial 4×4 transform matrix T that provides movement of thecamera300 without rotation given the x,y,z sphere end point. Then, theprocessor4102 and/or therobotic arm controller4106 calculate local roll and pitch amounts such that thecamera300 remains locked at a target located at x,y,z (and/or positioned at the x,y,z sphere end point) for subsequent cycles of joint rotations. Theprocessor4102 and/or therobotic arm controller4106 may use Equations (4) and (5) below to calculate roll and pitch amounts, where T_nextcorresponds to a 4×4 transform matrix. The calculations can be performed at each update cycle (e.g., 8 ms).
• $\begin{array}{cc}{T}_{\mathrm{next}}=T\left(\begin{array}{cc}\mathrm{<figure-callout\; label="R"\; filenames="US20190327394A1-20191024-D00042.png,US20190327394A1-20191024-D00051.png"\; state="\{\{state\}\}">R</figure-callout>}& 0\\ 0& 1\end{array}\right)& \left(4\right)\end{array}$
• • such that:
  • Xtarget_next=Xtarget
  • Ytarget_next=Ytarget
  • Ztarget_next=Ztarget
• $\begin{array}{cc}R=\left[\begin{array}{ccc}\cos \theta & 0& \sin \theta \\ 0& 1& 0\\ -\sin \theta & 0& \cos \theta \end{array}\right]\left[\begin{array}{ccc}1& 0& 0\\ 0& \cos \theta & -\sin \theta \\ 0& \sin \theta & \cos \theta \end{array}\right]& \left(5\right)\end{array}$
• In Equation (4) above, X_{target_next}, Y_{target_next}, and Z_{target_next}are constraints on the T_nextmatrix. The above-constraints specify that the roll and pitch angles are chosen such that the x,y,z equations above are valid. In other words, the x,y,z location of a target at a next update cycle of joint rotations has to be equal to the x,y,z location of the target in the current cycle. The constraints enable thecamera300 to be rotated via roll and pitch angles but remained locked relative to the x,y,z location.
• Further, −sin θ on the bottom row of the first matrix of Equation (5) corresponds to a pitch angle while sin θ on the bottom row of the second matrix corresponds to a roll angle. A closed form expression for pitch may exist given function cos(roll). Theprocessor4102 and/or therobotic arm controller4106 may use an iterative method to estimate roll, calculated as function cos(roll), with pitch equal to fn(cos(roll)) to generate a correct roll/pitch solution pair for the equations above.
• After the roll and pitch amounts are calculated from the operations described in connection withblocks6416 and6418, theexample processor4102 and/or therobotic arm controller4106 are configured to provide singularity avoidance and calculate inverse kinematics to determine joint rotation to achieve the roll and pitch amounts in addition to the new x,y,z position of thecamera300 along the virtual sphere6500 (blocks6214 and6420). The calculation of the inverse kinematics enables theprocessor4102 and/or therobotic arm controller4106 to determine a movement sequence for joints of therobotic arm506 and/or thecoupling plate3304.
• Theexample processor4102 and/or therobotic arm controller4106 may apply error correction for the movement sequence in addition to joint speed limits and/or position limits (blocks6418,6218,6220). As discussed above in connection withFIG. 62, the limits and error correction may prevent therobotic arm506, thecamera300, and/orcoupling plate3304 from hitting themselves, exceeding one or more boundaries, and/or being within acceptable joint positions. Theprocessor4102 and/or therobotic arm controller4106 may also validate commands for the joints of the movement sequence provide anti-noise filtering before sending the commands (or signals indicative of the commands) to one or more joints R1 to R9 of therobotic arm506 and/or thecoupling plate3304 based on the movement sequence (blocks6224,6226,6228). Theexample procedure6400 may then end if no other movement is detected. Otherwise, theprocedure6400 is repeated at periodic intervals (e.g., 10 ms, 20 ms, etc.) as operator inputs are received.
• In some embodiments, theprocessor4102 and/or therobotic arm controller4106 may provide lock-to-target tracking for instruments. In these examples, the xyz target of a center of thevirtual sphere6500 is replaced with a dynamic trajectory that corresponds to a moving target. Such a feature may enable a tracking of spinal tools, for example. In these embodiments, an instrument may include one or more fiducials and/or other markers. The examplestereoscopic visualization camera300 records images that include the fiducials. Theprocessor4102 and/or therobotic arm controller4106 may perform a coordinate transform from the camera frame space to robot space to determine how the instrument is being moved along the x,y,z axes. Theexample processor4102 and/or therobotic arm controller4106 track how the fiducials move in the image and determine the corresponding x,y,z movement vectors. In some instances, the x,y,z vectors may be input into the sphere end point calculation ofblock6414 ofFIG. 64 to change the location of a center of thevirtual sphere6500. In response to a movement of thesphere6500, theprocessor4102 and/or therobotic arm controller4106 determine how therobotic arm506 is to be positioned to maintain the same working distance and/or orientation with the new target location. Theprocessor4102 and/or therobotic arm controller4106 may then apply inverse kinematics to determine joint rotations of therobotic arm506 and/or the coupling plate to track the movement of the target. Similar to theprocedures6200 and6400, theprocessor4102 and/or therobotic arm controller4106 may apply error correction, joint limits, filters, and/or validation before sending commends to joints as specified in a determined movement sequence.
CONCLUSION
• It will be appreciated that each of the systems, structures, methods and procedures described herein may be implemented using one or more computer programs or components. These programs and components may be provided as a series of computer instructions on any conventional computer-readable medium, including random access memory (“RAM”), read only memory (“ROM”), flash memory, magnetic or optical disks, optical memory, or other storage media, and combinations and derivatives thereof. The instructions may be configured to be executed by a processor, which when executing the series of computer instructions performs or facilitates the performance of all or part of the disclosed methods and procedures.
• It should be understood that various changes and modifications to the example embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. Moreover, consistent with current U.S. law, it should be appreciated that 35 U.S.C. 112(f) or pre-AIA 35 U.S.C. 112,paragraph 6 is not intended to be invoked unless the terms “means” or “step” are explicitly recited in the claims. Accordingly, the claims are not meant to be limited to the corresponding structure, material, or actions described in the specification or equivalents thereof.

Claims (21)

The invention is claimed as follows:

1. A robotic imaging apparatus comprising:

a base section configured for connection to a secure structure or a cart;

a robotic arm including

a first end connected to the base section,

a second end including a coupling interface, and

a plurality of joints and links connecting the first end to the second end, each joint including a motor configured to rotate the joint around an axis and a joint sensor configured to transmit a position of the respective joint;

a stereoscopic camera connected to the robotic arm at the coupling interface, the stereoscopic camera configured to record left and right images of a target surgical site for producing a stream of stereoscopic images of the target surgical site;

a sensor positioned at the coupling interface and configured to detect and transmit output data that is indicative of translational and rotational force imparted on the stereoscopic camera by an operator;

a memory storing at least one algorithm defined by one or more instructions and/or data structures that specify a rotation direction, speed, and duration for each of the joints of the robotic arm based at least on a current position of the robotic arm and detected translational and rotational forces; and

at least one processor communicatively coupled to the sensor and the robotic arm, the at least one processor configured to:

receive the output data from the sensor that is indicative of the translational and rotational forces,

determine, using the at least one algorithm in the memory, a movement sequence for the robotic arm based on a current position of the robotic arm and the output data from the sensor, and

cause at least one of the joints of the robotic arm to rotate based on the determined movement sequence via one or more motor control signals provided to the at least one joint,

wherein the rotation of the at least one joint provides power-assisted movement of the robotic arm based on the detected translational and rotational forces imparted on the stereoscopic camera by the operator.

2. The apparatus ofclaim 1, wherein the at least one processor is configured to determine the current position of the robotic arm based on output data from the joint sensors of the plurality of joints.

3. The apparatus ofclaim 1, wherein the sensor includes at least one of a six-degrees-of-freedom haptic force-sensing device or a torque sensor.

4. The apparatus ofclaim 1, wherein the stereoscopic camera includes at least one control arm having a release button to enable the power-assisted movement, and

wherein the at least one processor is configured to:

receive an input message indicative that the release button was selected; and

determine the movement sequence using the output data from the sensor after receiving the input message related to the release button.

5. The apparatus ofclaim 1, further comprising a coupling plate with a first end configured to connect to the coupling interface of the robotic arm and a second end including a second coupling interface configured to connect to the stereoscopic camera,

wherein the coupling plate includes at least one joint including a joint sensor configured to transmit a position of the respective joint and a motor that is controllable by the at least one processor according to the movement sequence.

6. The apparatus ofclaim 5, wherein the sensor is located at the coupling interface or the second coupling interface.

7. The apparatus ofclaim 5, wherein the coupling plate includes a second joint that enables the stereoscopic camera to be manually rotated by an operator between a horizontal orientation and a vertical orientation, wherein the second joint includes a joint sensor configured to transmit a position of the second joint.

8. The apparatus ofclaim 1, wherein the stereoscopic camera includes a housing including a bottom side that is configured to connect to the robotic arm at the coupling interface.

9. A robotic imaging apparatus comprising:

a robotic arm including

a first end for connection to a secure structure,

a second end including a coupling interface, and

a plurality of joints and links connecting the first end to the second end, each joint including a motor configured to rotate the joint around an axis and a joint sensor configured to transmit a position of the respective joint;

an imaging device connected to the robotic arm at the coupling interface, the imaging device configured to record images of a target surgical site;

a sensor positioned at the coupling interface and configured to detect and transmit force and/or torque output data that is indicative of force and/or torque imparted on the imaging device by an operator; and

at least one processor communicatively coupled to the sensor and the robotic arm, the at least one processor configured to:

receive the force and/or torque output data from the sensor,

convert the force and/or torque output data into translational and rotational vectors,

determine, using kinematics, a movement sequence for the robotic arm based on a current position of the robotic arm and the translational and rotational vectors, the movement sequence specifying a rotation direction, a speed, and a duration of movement for at least some of the joints of the robotic arm, and

cause at least one of the joints of the robotic arm to rotate based on the determined movement sequence via one or more motor control signals provided to the at least one joint.

10. The apparatus ofclaim 9, wherein the processor is configured to:

determine a least one scale factor based on at least one of the current position of the robotic arm or a future position of the robotic arm based on the movement sequence; and

apply the scale factor to at least one joint speed of the movement sequence.

11. The apparatus ofclaim 10, wherein the at least one scale factor is configured based on a distance of the robotic arm or the imaging device from a virtual boundary, and

wherein the at least one scale factor decreases to a value of ‘0’ as the virtual boundary is approached.

12. The apparatus ofclaim 11, wherein the virtual boundary corresponds to at least one of a patient, a medical instrument, or operating room staff.

13. The apparatus ofclaim 11, wherein the processor is configured to cause a display device to display an icon indicative that the at least one scale factor has been applied to the movement sequence.

14. The apparatus ofclaim 9, wherein the processor is configured to:

determine a least one scale factor based on joint angles between joints of the robotic arm or joint limits; and

apply the scale factor to at least one joint speed of the movement sequence.

15. The apparatus ofclaim 9, wherein the processor is configured to:

provide gravity compensation for the force and/or torque output data; and

provide force-application compensation for the force and/or torque output data to compensate for an offset between a location of the sensor and a location of the imaging device upon which the force and/or torque is imparted by the operator.

16. The apparatus ofclaim 9, wherein the processor is configured to:

determine or identify joint singularities for the plurality of joints of the robotic arm for control of hysteresis and backlash; and

determine the movement sequence based on the kinematics while avoiding robotic arm movement through the joint singularities.

17. The apparatus ofclaim 9, further comprising a coupling plate with a first end configured to connect to the coupling interface of the robotic arm and a second end including a second coupling interface configured to connect to the stereoscopic camera,

wherein the coupling plate includes at least one joint including a joint sensor configured to transmit a position of the respective joint and a motor that is controllable by the at least one processor according to the movement sequence, and

wherein the sensor is located at the coupling interface or the second coupling interface.

18. The apparatus ofclaim 17, wherein the robotic arm includes at least four joints and the coupling plate includes at least two joints.

19. The apparatus ofclaim 9, wherein the processor is configured to cause at least one of the joints of the robotic arm to rotate by transmitting one or more command signals to the motor of the respective joint indicative of the rotation direction, the speed, and the duration of movement as specified by the movement sequence.

20. The apparatus ofclaim 9, wherein the processor is configured to compare images recorded by the imaging device as the robotic arm is being moved during the movement sequence to confirm the robotic arm is being moved as determined during the movement sequence.

21. The apparatus ofclaim 9, wherein the kinematics includes at least one of inverse kinematics or Jacobean kinematics.

Images